Front End

[SPORT]

Greetings gang,

For the last year or so a clunking noise can be heard & felt in the handlebars. It began on a road trip while the bike was loaded, including the top box. Upon returning I removed the top box and didn't notice anymore clunking. This clunking happend while riding over rough roads. When on another road trip with bike fully loaded (including the top box) again the clunking returned. Adjusted steering stem torque and checked for any loose bolts in and around the front end. Not too much later I went on another road trip and the clunking returned, but went away when tail box removed. But it progressively became more pronounced over time. Now the clunking continues whether the tail box is on it or not and only while riding over rougher roads. I just spent the last several days playing with the steering adjustment (following several prescribed procedures including torquing to 80lbs, turn the bars left and right 20 or so times with the front end off the ground, then backing it off and re-torquing to 37lbs.) It still clunks.

Now I'm beginning to think its in the front suspension. Any thoughts or suggestions?

Full Ohlins rebuild may be my next consideration.

Thanks

Rick

 

[r1byker]

I'm confused; you're torquing the steering stem nut to 80 and then backing it off to 37 ft. lbs.? It's supposed to be torqued to 80 (or somewhere around there) and then left there.

 

[RadioHowie]

I may be completely off base here, but since the noise first showed up with the top box attached, maybe you've had a "Rear Subframe Misadventure" and you're being fooled into thinking the noise is originating in the front end.

And IF the rear subframe is the issue, possible damage may be so far along, you're feeling/hearing the clunking over bad roads even without the topcase attached?

I'd grab a flashlight and take a good look at the rear subframe in the areas shown in the attached link.

 

[FJRmogul]

OK this is just a shot in the dark....

I had a clunking noise on rough roads a couple of years ago......it was one of my front rotors that developed a lot of play in the mounting bolts. Replaced and noise was gone. If you use your front brake while the klunking is there and it goes away then it's you rotors. Good luck in finding your noise.

 

[Patriot]

it was steering head bearings that needed replacement at 90k miles on my '04

was cured, but lately have the click on hard braking which is rotor bolts/mounts loosening up

prob have that delt with at next front tire change

 

[Fred W]

I'm confused; you're torquing the steering stem nut to 80 and then backing it off to 37 ft. lbs.? It's supposed to be torqued to 80 (or somewhere around there) and then left there.

Yes, you are confused.

The steering head bearing adjustment procedure is to torque them to 37 ft lbs, then loosen it one full turn and re-adjust it to 13 ft lbs.

The idea is to be sure the bearing is fully seated before making the final adjustment.

Sport, my guess is that your bearings are toast from running them at too high a torque.

Might be a good time to switch to some tapered roller bearings. In any case, it can't hurt.

 

[FJR Flyer]

Interested in this thread, as I, too, have had a clunking appear on rough roads. I'll have to take a look at the sub-frame. My first thought was to re-torque, the steering head. Still need to do that.

 

[redtail]

Had a similar clunking that I could feel/hear. Thought it was from front, and had ordered a steering nut tool. Went to GP suspension for a re-build of the front forks, and replaced the rear shock with a penske.

They showed me where the rear shock had been bottoming out. Not only was the clunking gone, but I was amazed at what real suspension felt like!

( 28,000 miles on an '05, at the time of the GP trip)

 

[Bustanut joker]

Oh ****! Another reason to hate the Fjr.... gotdamn heat, sidestand , mirors, seat, stalls, handlebars, vibration...

I wonder why anybody rides these fukin jap hunks of ****.. :blink:

:jester:

 

[SPORT]

Sport, my guess is that your bearings are toast from running them at too high a torque. Might be a good time to switch to some tapered roller bearings. In any case, it can't hurt.

Fred, For the most part I followed THIS and THIS thread. I had originally tried the 37 backed off to 13, but did not work. Then I increased to 45 and back to 13FT lbs. Now based on some of what I read, I figured torquing to 80Ft lbs may be required to seat the seat. I did not ride around with the excessive torque; thus, there should not be any damage. Besides, if the bearings were damaged, then I should have felt it when the front was in the air and I turned the bars left & right. It's still glass smooth in every position.

Somebody mentioned the sub frame...Gotta admit, I chuckled with that one. As if I didn't know my *** from my head (Don't answer that ). There is no damage to my sub frame. The reason I think the clunking was more pronounced with tail box is that it lightened the front end enough to move around when bumping through rough roads.

It is not the discs as they are tight (that would be a clicking anyway)...the calipers are also tight as is the wheel axle & bolts.

The clunking can also be felt/heard in the bars during an initial firm squeeze of the brakes while slowing down from speed.

Are the suspension springs prone to noise or perhaps the suspension bushings???

I've narrowed it down to either the Fork Tube bushings or somehow it's still in the steering head.

I am looking into the tapered bearings. Just don't think there necessary yet.

Again, I do appreciate the insights & suggestions.

 

[madmike2]

Not trying to be a smart aleck as you've obviously owned other bikes, and I assume you've tried moving the fork tubes in order to check for loose bearings, but....

Have you checked everything to make sure something isn't flopping in the front of the bike. Seriously, I had a horn that was loose and would flail a bit when I squeezed the brake. It gave a slight thumping sound and I could feel "something" in the handle bars when I rolled over the curb to ride up my driveway to the garage.

I also assume you've checked the front axle torque and pinch bolts. Try "jiggling" anything you can get your hands on: horns, radiator, fairing (a loose stay or bracket "could" transmit" sound and movement.

I'm crossing my fingers that it's something simple.

 

[BkrK12]

Take a look at the ABS ring in the front. On the GEN II bikes it can make a clunking sound which you can duplicate manually. Might do that on the Gen Is also.

 

[SPORT]

Have you checked everything to make sure something isn't flopping in the front of the bike. Seriously, I had a horn that was loose and would flail a bit when I squeezed the brake. It gave a slight thumping sound and I could feel "something" in the handle bars when I rolled over the curb to ride up my driveway to the garage.
I also assume you've checked the front axle torque and pinch bolts. Try "jiggling" anything you can get your hands on: horns, radiator, fairing (a loose stay or bracket "could" transmit" sound and movement.

I'm crossing my fingers that it's something simple.

Hmm; Good Idea. It sounds so much like steering head or fork bushings that I haven't really inspected much else as it sounds like two heavy objects hitting. I'll check this AM. As stated earlier, front axle is torqued and pinched correctly.

Take a look at the ABS ring in the front. On the GEN II bikes it can make a clunking sound which you can duplicate manually. Might do that on the Gen Is also.

I'll do that as well.

Thanks

I've been a mechanic 10+ years; once in a while you come across something that makes you scratch your head in wonder. :crazy:

 

[Fred W]

+1 on the above.

Here's an account of the ABS plate not being properly aligned causing some front end noises on a 1st gen w/ ABS, one of which was a clunk.

Certainly worth the quick check.

 

[SPORT]

Had a similar clunking that I could feel/hear. Thought it was from front, and had ordered a steering nut tool. Went to GP suspension for a re-build of the front forks, and replaced the rear shock with a penske. They showed me where the rear shock had been bottoming out. Not only was the clunking gone, but I was amazed at what real suspension felt like!

( 28,000 miles on an '05, at the time of the GP trip)

Redtail, thanks.

Unfortunately I'm just a little guy (according to Wild72) as I'm 155lbs soaking wet; so bottoming out is unlikely. Also, the clunking occurs during bumps that are MUCH less than what would bottom out. As shared I can squeeze the front brake while stopped and rock the bike back and forth. When the front end begins to dive I can sometimes hear the clunk (It's really telling me it's the steering head, but I've worked it as much as I can. The only other thought is that the seats are doing the clunking. If that's the case I have bigger problems!!!)

 

[SPORT]

+1 on the above.
Here's an account of the ABS plate not being properly aligned causing some front end noises on a 1st gen w/ ABS, one of which was a clunk.

Certainly worth the quick check.

Fred,

Thanks, but that's not the issue (I couldn't even see how that's possible; but...)

I also checked for anything else that may be loose in and around the front end. Everything is tight.

While bike on center stand I stood on pegs, squeezed front brake and rocked the bike back & forth fairly agressively. At the same time I placed fingers between the bike's frame and the triple tree. There is NO relative motion between the two, so I don't think it's in the steering head. however, now it seemed more like it's coming from within the forks. Probably bushings. Guess it's time for a rebuild.

Any ideas on the best front suspension upgrade?

 

[mcatrophy]

...While bike on center stand I stood on pegs, squeezed front brake and rocked the bike back & forth fairly agressively. At the same time I placed fingers between the bike's frame and the triple tree. There is NO relative motion between the two, so I don't think it's in the steering head. however, now it seemed more like it's coming from within the forks. ...

Are you 100% sure it's not a front brake rotor? Squat beside the front wheel, grasp the rotor in both hands, try to rotate it one way then the other. Repeat on the other side. If it gives you the clunk, relax, it's not a problem, just the floating rotor floating. Mine's being doing it for the whole of its life, I just accept that sometimes it clunks.

 

[SPORT]

Are you 100% sure it's not a front brake rotor? Squat beside the front wheel, grasp the rotor in both hands, try to rotate it one way then the other. Repeat on the other side. If it gives you the clunk, relax, it's not a problem, just the floating rotor floating. Mine's being doing it for the whole of its life, I just accept that sometimes it clunks.

Absolutely, positively, 100% sure. but for you; I'll check again.

 

[SPORT]

mcatrophy,

Just checked again. I tried forward, backward and lateral movement of the brake discs. The brake discs do not budge. Also re-checked the wheel, calipers, ABS sensor plate and other items. Nothing moves.

I did however hear movement from the mounting points of the front fender when I pushed the forks aft from the axle. The only reason why this might happen is if there is some kind of flexing of the outer/lower fork housing. It is rather odd, but there are NO cracks , leaks, or other signs of distres within the fork housing and the mounting bolts are tight.

Still left with the clunking residing within the Forks itself.