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I have 04 vfr800 non abs. I replaced the stock brake lines with galfer steel braided lines. The installation has gone well until I try to put the banjo bolt into the proportional control valve (the line that runs from the rear caliper to the PCV). It leaks from the washer between the banjo and pcv no matter how much I tighten it. It gets to the point where it strips the threads of the PCV. The galfer installation manual says it has a torque spec of 15-17 ft/lbs but the service manual doesn't have a torque spec. It never tightens down by ratchet or with torque wrench and keeps spinning, which causes the threads to strip. Ive tried using the stock banjo bolt and the new one from the kit. I already went through 2 PCV units and not trying to mess it up again. Im going to see if the stock washers make a difference on the next attempt but I want to make sure I'm not doing anything else incorrectly. Anyone else have issues with the same or similar installation? I appreciate the help! Extra context: The front left brake caliper was refilled properly with brake fluid and had no leaks, so I know it should work. I noticed the leak when trying to fill the rear line with fluid.
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A little background first... I've been riding about 8 years now; started with a 2005 Ninja 500, then 3 years ago I made the move and upgraded to a 2002 VFR800. I was looking specifically for a 2009 in white/black (as I find this to be the best looking bike on the road), but when I saw a 2002 painted in that exact color scheme (!!!) on Kijiji for about half the price the 09's were going for, I knew what was going to happen next... and 2 days later I own a 2002 VFR800! 43,000km or so, currently at about 54,000km. 'Mods' when I bought it: - Repainted in '09 White/Black, no decals on the bike - all logos are airbrushed - Carbon Fibre-ish gas cap cover - Carbon Fibre-ish mirrors - Carbon Fibre-ish barends - Carbon Fibre-ish tank pad - Black Double-bubble windscreen - LED license plate bolt bulbs Mods to date: - Carbon Fibre-ish triple cover - Clear front signal lenses - Heli-bars - Pro Grips - Power Commander 5 - Corbin Seat - Honda Factory Sidebags - Fiamm Freeway Blaster Horn - Battery Tender Jr SAE harness (and BT SAE->USB adapter for charging) - RK Gold XW 520 Chain conversion with steel -1+2 sprockets - EBC HH sintered rear brake pads - De-snorkeled, de-flappered, PAIR removed JUST ADDED: - Autotune - Aftermarket clear/red taillight - "Chrome-dome" turn signal bulbs - full amber glow, only chrome tipped not fully dipped, but when off show silver when facing bike (in transit) - Gear indicator (cheapy Chinese eBay unit - have not finalized the pickup locations as my forks are still off, need to get it on road to test it) - Volt meter (eBay cheapy from China) - SpeedoDRD to correct changed gearing and factory inaccuracy - 6sigma PAIR blockoff plates - VFRness - Ricks R/R - Jamie D rear shock (CBR600F4), fully adjustable cartridge kit in forks - Replaced carbon-fibre look barends with OEM black barends - Replaced carbon-fibre look mirrors with OEM black mirrors - New starter relay / connector / wiring (due to melting, see thread "crispy starter solenoid") - Went through every connector and as much wiring as I could access to ensure nothing else is burned/melted/needed to be replaced. Dielectric grease ftw - New rear Pirelli Angel GT - Replacement OEM Honda spark plugs - Chinese adjustable/foldable black/titanium levers Mods to come: - 8 spoke 90-93 rear wheel (working on finding one) - Sebspeed clear clutch cover - Staintunes (possibly) - Rear OEM topcase (possibly) Its been a fun winter of farkling... If anyone wants details on install of any parts, or any specific pictures, post up or PM me! Pics (taken today 07/04/2015)
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From the album: MadScientist's Gallery
Splices for speedo and tach for PC-V