OEM Banjo bolt washer! - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 22 Old 02-01-2018, 09:22 PM Thread Starter
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OEM Banjo bolt washer!

Changed out the brake lines with Galfer SS lines. I began bleeding them and i noticed that brake fluid was leaking from the banjo bolt washer. The leaks only came from the front brake lines and not the back ones. The galfer kit came with the copper crush washer and after comparing them to OEM ones the Galfer ones have a smaller outer diameter. I bought some new copper washers and installed them but the leak was still there. I torqued them to 16.5 lb ft. I'm trying to get a hold of some new aluminum washers that have the same diameter as the oem ones. Can any one recommend me some quality banjo bolt washers. I just want to ride my bike!

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post #2 of 22 Old 02-02-2018, 10:47 AM
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Originally Posted by IHellsent View Post
Changed out the brake lines with Galfer SS lines. I began bleeding them and i noticed that brake fluid was leaking from the banjo bolt washer. The leaks only came from the front brake lines and not the back ones. The galfer kit came with the copper crush washer and after comparing them to OEM ones the Galfer ones have a smaller outer diameter. I bought some new copper washers and installed them but the leak was still there. I torqued them to 16.5 lb ft. I'm trying to get a hold of some new aluminum washers that have the same diameter as the oem ones. Can any one recommend me some quality banjo bolt washers. I just want to ride my bike!

Seems weird that new washers would leak. Did you look at the surface of the banjo bolt itself, maybe there's a burr or sumpthin'.

Did you go to a good auto parts store for the washers or a hardware store? Actual copper crush washers won't be hard annealed like hardware washers probably.

Seen these Stat-o-seal washers?


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post #3 of 22 Old 02-02-2018, 11:04 AM
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Do they leak only under pressure or already when bleeding?

Is probably not the washer but one of the fittings dinged or otherwise compromised.

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post #4 of 22 Old 02-02-2018, 12:45 PM
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Spec, thanks for that stat-o-seal link. Never seen those. I went digging into the mfg catalog and they make them with many different kinds of rubber and other materials, many of which are not brake fluid compatible. And, of course, some are. Worth noting so as not to buy them generically. Get the proper ones and I bet those things are a big help when necessary. Or one hell of a liability if you get the wrong type.
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post #5 of 22 Old 02-02-2018, 10:14 PM
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You can always try using the original washers if you still have them. If they work, they work. Doesn't matter how old they are.
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post #6 of 22 Old 02-02-2018, 10:15 PM
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They are crush washers. They harden with use and are less likely to conform.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
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post #7 of 22 Old 02-03-2018, 02:19 AM
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They are crush washers. They harden with use and are less likely to conform.
Aluminum work-hardens. An old welder's trick I know to anneal/re-use an old aluminum crush washer I've done with an oxy-acetylene torch. If you have one, you use an acetylene flame to cover the part in soot, and then add in oxygen and use the neutral flame to heat the part until the soot blows back off. You could probably use a kerosene lamp or a candle to soot the part up and then heat with any garden-variety propane torch. Let it cool slowly and naturally (don't quench) and it should be annealed and reusable. If there are any obvious surface defects, once annealed you can sand on emery cloth laid on a flat surface to clean up any burrs, etc.

Last edited by RidgeRunner729; 02-03-2018 at 02:23 AM.
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post #8 of 22 Old 02-03-2018, 06:53 AM
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Annealing-Shmealing - Interesting display of oil pan washers at the local cycle shop.
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post #9 of 22 Old 02-03-2018, 09:04 AM
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PM sent. You are only about an hour and half from Galfer's facility. I'm sure they will get you what ever you need.
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post #10 of 22 Old 02-03-2018, 02:43 PM Thread Starter
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Thanks for all the replies and sorry for the long reply. When i would apply pressure on the lever a leak appeared on the master cylinder, the divider piece (both sides). All the surfaces were smooth and free of dirt. Here is a pick of the oem washer and the one that came with the galfer kit.
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1990 Suzuki GS500e (First POS Bike)
2006 Honda 919 (First reliable bike) SOLD
2015 Honda Grom (Fun bike)
2011 Suzuki Vstrom 650 (Adventures to come)

High-Viz Every Day!

Life isn't what's around the corner, it is the corner!
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