Front end went solid

[seth]

Hiya all
On our recent trip back from Belgium
The forks on Emma's gsx1400 went really hard with very little movement at all.
When I stripped them down the forks and removed the topcaps a fair bit of compressed air came out .
I know this isn't normal and was wondering if anyone else as ever come across this ?

I haven't found any major problems and will be replacing the bushing as they are slightly worn ( 55,000 miles)
And replacing the oil .
Hopefully this will fix the problem and all will be good again .

[Andre]

No real idea about that. Hydro lock popped first into my mind. I would clean everything really good and inspect all the passages (valves, pipe) that they are not blocked. 

[Hooli]

It's a new one on me too.

I'd go with Andre's suggestion to ensure all the holes are clear. I'm trying to think how extra air could have got sucked in but can't really think of anything.

[seth]

Only thing I can think is
The upper seal's spring had rusted away and air had got in over time by pulling air into the forks as there were no leaks of oil

Everything is going to be replaced with new seal's bushes and oil .

[Hooli]

Seems odd air got in but not out again. Had to be something like that though I'd guess.

[seth]

Well all stripped cleaned and rebuilt with new oil,seals and bushes.
All seams fine now so fingers crossed the test ride goes well.
Only think I can think of is the upper seal spring that had rusted away allowing air into the forks on the up stroke but not out on the down stroke.
One of the bushes was a bit worn so replaced all the bushes.

[seth]

One thing is add is I didn't have time to wait for Suzuki bushes (My preferred option) do to needing the bike for another european trip.
so ordered from pyramid parts (a UK company) and although they came quickly enough I had to fettle the lower bushes as they were slightly to big to fit the sliders .
I had to re-cut the slot in the bushes and then close them up by about 1-1.5mm on the od so everything then worked as it should and runs nice and smooth.
So just a warning that these parts that are only slightly cheaper than stock didn't fit quiet as easily as they should of and I think Suzuki ones would have been more straight forward to fit (My problem was time not price)
I did use genuine Suzuki Fork seals.
Emma says that on the approx 800 mile weekend trip to Belgium said the bike now feels so much better and nicer to ride.

[Hooli]

I've heard the 'all-balls' ones made in the USA fit properly, I think wemoto do them.

No use to you I realise.

[seth]

Cheers @Hooli
I will look into webmoto as I have another set of folks to service soon and I like to keep a spare set of consumable parts in the garage .

[Andre]

Anything I got from All-Balls and Tourmax has been very good so far

[froudy]

Cheers @Hooli
I will look into webmoto as I have another set of folks to service soon and I like to keep a spare set of consumable parts in the garage .

https://www.wemoto.com/bikes/suzuki

Fork rebuild kit..Not sure about seal quality though. Like you Seth, I'd rather use genuine Suzuki OEM.
https://www.wemoto.com/bikes/suzuki/gsx_1400_k7_fe/07/picture/fork_repair_kit_-_slinky_glide

[Mick_J]

I have used all balls racing seals and they are fine, got them on my speedtriple.