Front Brake Problem

[Pezman4200]

Progress!!

When I originally took apart master I did not take out piston because I didn't have any replacement parts and if I was going to take it apart I wanted to install a rebuild kit.  So I found a rebuild kit at a local yamaha dealer and took master apart, cleaned and installed new piston and seals. Inside the piston area was pretty clean and I didn't notice anything that jumped out at me. I cleaned the two holes in the bottom of the master and the smaller return one did have some gunk around it. (Thinking that was ultimately my issue) 
So, rebuilt master installed, new brake lines installed, complete new fluid throughout and even though I was able to bleed calipers and get nice clean, air free, fluid out of bleed screw I still could not get any brake lever!  Soft and would squeeze to bar with no application of brakes!
Frustrated for sure! 
After some time saying to myself ........ WTF am I missing? 
After seeing one of the original banjo bolts under the bike with the old lines, I decided to install the original banjo bolts into master, and calipers!

Instantly got pressure in brake lever!  Repeated bleeding! Brakes work perfect and feel much better than they did before.
Unbelievable that the fricken banjo bolts in the kit have a much smaller diameter hole in thm for the fluid to pass through.

Anyone experience this.  They are Galfer brake lines for the FJ1200.

[shockeymon]

Just bought the Galfer lines myself, haven't had a chance to put them on yet, but thanks for saving me a lot of time & headaches!