I put in a new starter in my 2005 CBR600rr and after connecting the fuel hose to the tank I tested the pump and it sprayed me with fuel. I tried new sealing washers today and still it was leaking.
I fear the threads on the pump are somehow messed up, but before jumping the gun on a whole new fuel pump I'd like to try a new hose, banjo bolt, and washers. I can find the bolt and washers easily but the hose is not so easy to find.

I believe the part I need is #5 at the bottom, please do correct me if I'm wrong

It's that hose there that connects to the fuel pump.

If it is part #5 I don't know where to get it. I've looked here and it's not even a purchasable option. I've looked through numerous part websites and they all seem to be the same way.
My best bet seems to be ebay. I found a 03-04 600rr fuel hose line, but I'm not sure if that will fit the 05 models.
I also found an 05-06 fuel hose w injector rail but that's more expensive and comes with parts I don't need.

Thanks for reading, any input is appreciated. Also if you've experienced this problem and think I just need to shell out the money for a pump because you know these won't fix it let me know.

 

@Stewal Hi and welcome to the forum. So each banjo fitting has a sealing washer on each side, right? Is it leaking out from the sealing washers, or from some other fitting? The tip of the purple arrow is not really touching anything, so just wanting to be sure which hose it is and exactly where the leak is.

 

Hi sorry for the bad photo I found a better picture online so I can more clearly show it

This is where the leak is coming from. There was a sealing washer on both sides. The leak is (I think) coming from the back of the fitting where it meets the threads. It didn't leak at all until I turned on the pump and then it just sprayed out so it was hard to really tell where it came from.

 

Did you use new crush-washers?
Use torque-wrench to tighten banjo-bolt?

 

Yes I torqued it to 16 ft-lbs per service manual and tried new crush-washers

 

got it fixed with a new banjo bolt and sealing washers.
Now another starter problem :/
It only starts from the start button if the engine is already warm
if the engine is cool then i need to push start it

 

Glad you got the leak sorted out. What is the voltage across the battery when the bike is off, as well as when it's on? What about while it's starting?

 

I tested it with a very old multimeter that was pretty crappy and hard to read, but it appeared to be the same as my CB300F voltage which works fine. I'll be going to a buddies house to test it with his properly working multimeter sometime this week.
In the meantime I ordered a starter relay since they're cheap and it might fix it

 

How old is the battery?

 

Battery sticker says 5/22
I tested the voltage: 12.81 (bike off), 12.44 (bike on), 11.67-12 (starter being held)