Brake lines leaking

Ryan625
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Ryan625
Edited Date/Time 9/3/2020 8:59am
I have brand new brake lines on my RM project bike, brand new banjo bolts, and brand new copper crush washers. They are dripping around the sealing surface between the line and the caliper.

I had them locked down hard and it still wouldn’t seal. Any suggestions? Should I do any prep to the surface areas? I just had the calipers ceramic coated

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Rickyisms 9/1/2020 6:59pm
9/1/2020 6:59pm
I would sand down to bare metal where the crush washer meets to the caliper and master cylinder and use fresh washers.
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Ryan625
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Ryan625 9/1/2020 8:23pm
9/1/2020 8:23pm
Rickyisms wrote:
I would sand down to bare metal where the crush washer meets to the caliper and master cylinder and use fresh washers.
I was thinking the same. I don't know what else it would be and it does seem to only be on that side. I will probably sand the points where they meet on all 4 surfaces and see.
Ryan625
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Ryan625 9/1/2020 10:59pm
9/1/2020 10:59pm
Well sanding the surfaces didn't get the job done. I even swapped banjos and crush washers. I am out of ideas at the moment, but may end up ordering new lines and sending these ones back I guess, unless someone else has any ideas for me?
kb228
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kb228 9/2/2020 6:55am
9/2/2020 6:55am
Cerakote is thin enough to not cause any issues regarding surface sealing or making something not flat. Lots of people use it on brakes with no issue.

Only thing i can say is use quality parts from galfer or oem. Did you try your old lines?

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charlie68
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charlie68 9/2/2020 7:44am
9/2/2020 7:44am
If that banjo bolt is torqued on the caliper, your banjo bolts are too long the way I see it, Bolt bottoming and not tightening, will the line move when bolt is tight?
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Ryan625
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Ryan625 9/2/2020 12:50pm
9/2/2020 12:50pm
I am using brand new Tusk lines, from what I understand most of their parts are rebranded from quality brands. The Ride engineering billet banjo bolts are correct length.

I’m running out of ideas. I guess the next step is to give a name brand line a try 🤷🏻‍♂️
charlie68
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charlie68 9/3/2020 8:59am
9/3/2020 8:59am
Did you try moving the lines when torqued?
Also looking at the pics again, the coppers look like they could be too big, in a hydraulic application the copper should be about the O.D. of the banjo bolt.
I am sure you can get what you have to work without dumping more dough at it.
Ryan625
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Ryan625 9/5/2020 9:54pm
9/5/2020 9:54pm
Well I finally found the problem after looking everything over very carefully and then digging into my stack of receipts. I accidentally ordered an RM125 front brake line. I am using an entire front end off of an RMZ450 including brakes. This minor difference in lines was causing the line to hit the caliper to an almost unnoticeable degree and making it not seal. After pulling the line I gave it a few light taps with a dead blow while it was clamped into my bench vice and increase the bend in the neck at the connection point, and after that it sealed right up.

Thanks for all the suggestions guys!
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