Potential Disaster Averted - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 16 (permalink) Old 06-15-2019, 10:33 PM Thread Starter
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Potential Disaster Averted

So today I finished installing a new Gafler braided brake line on my 03 Volusia. I've had the bike for 8 years now and I know I've never changed it, so quite possibly the original 16 year old line. I had flushed and replaced the fluid since I've had it, but still the original line.

In the process of wrestling the bike around to position the master cylinder to expedite the fluid flush and refill, I noticed my handlebars were a little looser than normal. I've had to tighten them before, so nothing surprising. Get the appropriate socket and ratchet, make a few turns on the bottom of the left riser. Make a few more turns, and a few more turns.... uh, it won't tighten up. OK, move to the bottom of the right side, tightens up fine. I'm walking back around the front of the bike to try and tighten the left riser thinking it was really strange how it must have backed out that far, when I hear the bolt and associated washers fall out and hit the ground.

UH, OH.... not loose, but stripped out. Appears to me, whoever installed the risers, used a bolt that was not near long enough. Only about 1/2 inch of that bolt was threaded in the bottom of the riser. I've had the bike 8 years and never had a reason to mess with the bars as it fits me perfect.

I can only imagine what could have happened if that bolt had decided to turn loose on a mountain road, or any road for that matter. Dodged a bullet.

So, not going to mess with trying to tap the old riser. They're cheap enough to just replace. And you better believe, I'll have a longer bolt installed.
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post #2 of 16 (permalink) Old 06-15-2019, 10:37 PM
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Go buy a lottery ticket. Lucky.
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post #3 of 16 (permalink) Old 06-16-2019, 04:08 AM
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Good thing you caught that. If it wasn't for your wisdom to replace the brake line, you may have missed it. Every February I take time and go out and start checking and tightening any and all bolts.
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post #4 of 16 (permalink) Old 06-17-2019, 10:15 AM
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Quote:
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Go buy a lottery ticket. Lucky.
He just won the lottery... lucky indeed.
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post #5 of 16 (permalink) Old 06-17-2019, 10:18 AM
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You made me paranoid about this now... When I got the bike, I saw that it had risers installed with mismatching washers (doesn't affect much but style) but I never went to take them apart. Now I will do that as soon as possible...
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post #6 of 16 (permalink) Old 06-17-2019, 10:20 AM
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BTW, how was the Galfer line install? Do you notice a difference in braking power?

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post #7 of 16 (permalink) Old 06-17-2019, 04:46 PM
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OK. Two things.....

1) I'm headed out to the garage and going to check and tighten my risers. Good reminder!
2) Which Galfer line did you install? Probably should do mine too. I have an '01 Volusia

Good and lucky catch and a reminder to everyone to spend some time tightening things up occasionally. (No stupid comments from the peanut gallery on that last part)!
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post #8 of 16 (permalink) Old 06-17-2019, 04:48 PM
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post #9 of 16 (permalink) Old 06-17-2019, 05:16 PM
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Of all the things that could possibly come loose and fall off of my bike, I can't think of anything worse than the handlebars.
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post #10 of 16 (permalink) Old 06-18-2019, 08:08 AM
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Quote:
Originally Posted by FireManC50 View Post
BTW, how was the Galfer line install? Do you notice a difference in braking power?
I installed the Galfer line last night, and yes - there is a substantial increase in braking power up front. The front end of the bike actually pulls down now when I apply the front brake, it didn't do that before! I felt like most of my stopping power was coming from the rear. The brakes feel a LOT more balanced now.

Purchased this one:



I'm a novice mechanic, but I've done brakes on the car before so this didn't look too intimidating. Revzilla has a video on Youtube that walks you through the process step by step. Overall it took me 40 minutes to swap out the brake line. 10 of those minutes were spent crawling on the garage floor looking for the banjo bolt washer that I dropped. Finally found it under the lawnmower.

I bought a new set of brake pads also, but the pads on the bike now still look pretty good so I'm going to wait before swapping them out.

-CG
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