Middle Tennessee Dirt Riders

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Front brake leaks near Banjo bolt when I pull the lever.

  • April 01, 2019 1:42 PM
    Message # 7255375
    Deleted user


    Front brake on my 2009 KTM 250xcw leaks near Banjo bolt when I pull the lever.  This weekend I was riding at west point and went to pull the front brake and it was soft. Next time I pulled it went to the grip and nothing happened. Luckily i was going up hill (The down hill back the truck was not that fun). I found that the banjo was tight as can be but the reservoir was empty. I filled it back up and rode some more trying not to use my front brake. Today I pulled the lever and saw brake fluid coming from the area around the banjo so I ordered a new banjo the washers on each side and a cylinder rebuild kit. Anyone think I need to replace anything else other than brake fluid?


    Last modified: April 01, 2019 1:42 PM | Deleted user
  • April 01, 2019 4:10 PM
    Reply # 7255639 on 7255375

    Is there anything obvious wrong with the banjo or the copper washers, or the banjo bolt?

  • April 01, 2019 6:00 PM
    Reply # 7255793 on 7255375
    Deleted user

    Not that I can tell. I figured I might as well rebuild the master since the bike has hit 120hrs.

  • April 01, 2019 11:37 PM
    Reply # 7256248 on 7255375

    rebuilding the master cylinder is a 30 min job and about 25 to 30 dollars.  seems to go bad about every 100 hours.  much better feel and much safer to get it done. 

  • April 05, 2019 9:36 AM
    Reply # 7261635 on 7255375

    i have seen literly hundreds of of bikes over the last50 years,, never saw one go bad in a small hours of use,,my 2002 exc 250 had around 1000 hrs on it when i sold it, with no service except changing the fluid every time the pads were changed, the main piston seal would be leaking from around where the lever pushes the piston itself,,,crash damage is the main suspect,,,the fact that the piston is pushing out fluid suports this unexamed theory,,,bv615-746-5975

  • April 09, 2019 2:35 PM
    Reply # 7274334 on 7255375
    Deleted user


    When I pull the brake lever brake fluid leaks out and runs down the banjo. I only have a little over a hundred hours but the bike is a 2009. So 10 years + Rubber seals + brake fluid = New Cylinder. Does my math add up?

  • April 11, 2019 5:14 PM
    Reply # 7278634 on 7255375

    try replacing the crush washers on the banjo & inspect the bolt for BENT while apart or just replace the bolt & washers, about $5 & bleed & retest,,,bv

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