1985 GS 1150E fork tubes (problem)

[jstewart]

I pulled the front forks on my 1985 GS 1150E restoration project to service them (new fluid, seals, dust seals & general inspection). The forks were not leaking but had only 1/2 the specified fluid when drained. After assembly with the correct amount of fork oil I noticed the right inner fork tube seemed to have a leak laying on it's side on the bench. Careful inspection shows it is leaking from what appears to be a welded up spot between the two triple trees. Further inspection of both forks identified four spots (two on each fork tube) that had been welded & dressed down. Theses repaired points (two on each fork tube) are at the same location on both fork tubes. It appears there were holes in the same location located between the trees welded up on both fork tubes. One of these repairs only started to leak fork fluid after the correct amount of fork fluid was installed. These fork tubes also have the holes in the correct location for the air press. at the top triple clamp. Any ideas on why tubes would be drilled in this location (it can't be chance that each tube had corrosion holes in identical location on both tubes) ?????????????????????????????????????????????????????????

Just goes to show you never know what you are going to get into on a 30 year old bike restoration project.

Any suggestion on repair? New tubes are no longer available from Suzuki. They are available from Forking By Frank for $308.00 per set plus frt.

 

[Guest]

I think that one of the previous owners decided to relocate the air rings down lower so they could drop the front end by raising the forks up through the triples.

another sneaky leak point on those forks..... the shaft on the adjustment knob for the PDF / anti-dive valves. They can be blocked off completely if you install cartridge emulators.

Before i spent $308 on new tubes i would look into having the holes brazed or welded shut and spend the money on new springs and emulators.

 

[blowerbike]

i agree with the above statement...i have had the cross over holes welded closed in the past on pro street type's of GS's.
new tubes are nice but good used/unmodified would work to for less money.
pm me if you need anything.
terry