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[Robert J. Kaub]

Saturday I noticed my '98 making this clunking sound when I come to a stop and the front end does that little rebound as you stop. Loose head bearings came to mind so I decided to confirm the diagnosis by lifting the bike on the centerstand and doing the grab and shake the front forks thing. Here's where it gets strange. When doing the front fork shake I was unable to detect any looseness in the head bearings at all. I did this test twice several hours apart and could not feel any looseness. If the head bearings are not loose, then what is making the clunking sound. The front brake caliper is tight. Is there anything inside the forks which could loosen and clunk? Thanks. Bob Kaub

[squidwannabe@hotmail.com]

--- In DSN_klr650@y..., "Robert J. Kaub" wrote:

> Saturday I noticed my '98 making this clunking sound when I come to

a stop

> and the front end does that little rebound as you stop. > Loose head bearings came to mind so I decided to confirm the

diagnosis by

> lifting the bike on the centerstand and doing the grab and shake

the front

> forks thing. > Here's where it gets strange. When doing the front fork shake I

was unable

> to detect any looseness in the head bearings at all. I did this

test twice

> several hours apart and could not feel any looseness. > If the head bearings are not loose, then what is making the

clunking sound.

> The front brake caliper is tight. > Is there anything inside the forks which could loosen and clunk? > Thanks. > Bob Kaub

Could it be your instrument cluster ?

[Zachariah Mully]

Bob- Have you replaced your fork springs with progressives or done any work on the front suspension lately? I had this clunk after I had to pull my forks apart... Nothing changed in the setup, but after I assembled them, I think that the spacers weren't seated tight against the fork caps and so would click (or clunk, I guess, if you've got PVC spacers) whenever the front end would rebound hard (like coming into a stop light). I never did fix it, and I think that it went away eventually. Dunno if this is your case, but you might be able at least rule this out as a cause for your clunk. ------------------ Zack Banana Republic of Washington, DC KLR650A5 "Buster" ZG1000A1 1966 Vespa 125 COG #4664 -----Original Message----- From: Robert J. Kaub [mailto:rkaub@...] Sent: Monday, May 21, 2001 2:17 PM To: KLR Subject: [DSN_klr650] Clunk in the Front Saturday I noticed my '98 making this clunking sound when I come to a stop and the front end does that little rebound as you stop. Loose head bearings came to mind so I decided to confirm the diagnosis by lifting the bike on the centerstand and doing the grab and shake the front forks thing. Here's where it gets strange. When doing the front fork shake I was unable to detect any looseness in the head bearings at all. I did this test twice several hours apart and could not feel any looseness. If the head bearings are not loose, then what is making the clunking sound. The front brake caliper is tight. Is there anything inside the forks which could loosen and clunk? Thanks. Bob Kaub

[Robert J. Kaub]

Zack: I haven't done anything to the forks. They are completely stock including the oil. The bike has a little less than 10,000 miles on it. I do a high percentage of my riding on dirt roads with a lot of potholes, which I usually just ride through, so the front end takes more of a beating than a bike ridden mainly on paved roads.

[Phil Roddenberry]

Hey Bob, Check the stearing stem top nut for tightness... (the nut just below the handlebars, between the handlebar clamps) This 'nut' was loose on Lew Waterman's bike and was causing a 'clunking' sound. (I could turn it by hand) I loosened the lower front fork clamp bolts & nuts to free the fork tubes. Removed the handlebars to tighten the top stem nut, (29 ft/lbs torque) used a bit of 'blue' Loctite in hopes of preventing the nut loosening again. Tightened the lower front fork clamp bolts to 18 ft/lbs torque... replaced handlebar and tightened clamp bolts to 17.5 ft/lbs torque. No more 'clunk' in the front end! (all torque specs are from the Kawasaki service manual) Phil A-15 Live Oak, FL

--- In DSN_klr650@y..., "Robert J. Kaub" wrote: > Saturday I noticed my '98 making this clunking sound when I come to a stop > and the front end does that little rebound as you stop. > Loose head bearings came to mind so I decided to confirm the diagnosis by > lifting the bike on the centerstand and doing the grab and shake the front > forks thing. > Here's where it gets strange. When doing the front fork shake I was unable > to detect any looseness in the head bearings at all. I did this test twice > several hours apart and could not feel any looseness. > If the head bearings are not loose, then what is making the clunking sound. > The front brake caliper is tight. > Is there anything inside the forks which could loosen and clunk? > Thanks. > Bob Kaub

[punkynlew@hotmail.com]

Hi Phil and List: The steering stem nut and all other work Phil did on Critter are working perfectly. With 10k miles on the clock, nothing is loose, rattling or out of the ordinary. The adventure tour and experience of my lifetime is going very well, thanks to Phil and a lot of other very nice and helpful people. The overnight 2" of snow is mostly melted now here in the Black Forest of Colorado. Phil's advice about finding free places to camp has been invaluable as well. Swede and Bogdan were surprised that we could follow them anywhere they chose to go. However, if I choose to ride the famous White Rim near Moab, I will probably offload most of the gear and luggage. I'm now carrying the TKC80 rear tire that was removed at Enid, OK as a spare on top of the tailbox. Phil, I hope all is well on your homefront. Later. Punky & Lew

--- In DSN_klr650@y..., "Phil Roddenberry" wrote: > Hey Bob, > > Check the stearing stem top nut for tightness... (the nut just below > the handlebars, between the handlebar clamps) > > This 'nut' was loose on Lew Waterman's bike and was causing > a 'clunking' sound. (I could turn it by hand) > > I loosened the lower front fork clamp bolts & nuts to free the fork > tubes. Removed the handlebars to tighten the top stem nut, (29 ft/lbs > torque) used a bit of 'blue' Loctite in hopes of preventing the nut > loosening again. Tightened the lower front fork clamp bolts to 18 > ft/lbs torque... replaced handlebar and tightened clamp bolts to 17.5 > ft/lbs torque. No more 'clunk' in the front end! (all torque specs > are from the Kawasaki service manual) > > Phil A-15 > Live Oak, FL > > --- In DSN_klr650@y..., "Robert J. Kaub" wrote: > > Saturday I noticed my '98 making this clunking sound when I come to > a stop > > and the front end does that little rebound as you stop. > > Loose head bearings came to mind so I decided to confirm the > diagnosis by > > lifting the bike on the centerstand and doing the grab and shake > the front > > forks thing. > > Here's where it gets strange. When doing the front fork shake I > was unable > > to detect any looseness in the head bearings at all. I did this > test twice > > several hours apart and could not feel any looseness. > > If the head bearings are not loose, then what is making the > clunking sound. > > The front brake caliper is tight. > > Is there anything inside the forks which could loosen and clunk? > > Thanks. > > Bob Kaub

[Susan Moorhead]

Lew & Punky, Glad to hear things worked out in Enid re: new rear tire. Hope they took good care of you guys. We are keeping a file of your email messages to supplement the trip reports, web site, etc... Glad you two got to stop for a visit, good luck with the rest of your journey. Please know that you and Punky will be in our prayers. Travel safe, have fun. Marshall & Susan Moorhead Afton, Ok

----- Original Message ----- From: To: DSN_klr650@yahoogroups.com> Sent: Monday, May 21, 2001 4:15 PM Subject: [DSN_klr650] Re: Clunk in the Front > Hi Phil and List: The steering stem nut and all other work Phil did on > Critter are working perfectly. With 10k miles on the clock, nothing is > loose, rattling or out of the ordinary. The adventure tour and > experience of my lifetime is going very well, thanks to Phil and a lot > of other very nice and helpful people. The overnight 2" of snow is > mostly melted now here in the Black Forest of Colorado. Phil's advice > about finding free places to camp has been invaluable as well. Swede > and Bogdan were surprised that we could follow them anywhere they > chose to go. However, if I choose to ride the famous White Rim near > Moab, I will probably offload most of the gear and luggage. I'm now > carrying the TKC80 rear tire that was removed at Enid, OK as a spare > on top of the tailbox. Phil, I hope all is well on your homefront. > Later. > > Punky & Lew > > --- In DSN_klr650@y..., "Phil Roddenberry" wrote: > > Hey Bob, > > > > Check the stearing stem top nut for tightness... (the nut just below > > the handlebars, between the handlebar clamps) > > > > This 'nut' was loose on Lew Waterman's bike and was causing > > a 'clunking' sound. (I could turn it by hand) > > > > I loosened the lower front fork clamp bolts & nuts to free the fork > > tubes. Removed the handlebars to tighten the top stem nut, (29 > ft/lbs > > torque) used a bit of 'blue' Loctite in hopes of preventing the nut > > loosening again. Tightened the lower front fork clamp bolts to 18 > > ft/lbs torque... replaced handlebar and tightened clamp bolts to > 17.5 > > ft/lbs torque. No more 'clunk' in the front end! (all torque specs > > are from the Kawasaki service manual) > > > > Phil A-15 > > Live Oak, FL > > > > --- In DSN_klr650@y..., "Robert J. Kaub" wrote: > > > Saturday I noticed my '98 making this clunking sound when I come > to > > a stop > > > and the front end does that little rebound as you stop. > > > Loose head bearings came to mind so I decided to confirm the > > diagnosis by > > > lifting the bike on the centerstand and doing the grab and shake > > the front > > > forks thing. > > > Here's where it gets strange. When doing the front fork shake I > > was unable > > > to detect any looseness in the head bearings at all. I did this > > test twice > > > several hours apart and could not feel any looseness. > > > If the head bearings are not loose, then what is making the > > clunking sound. > > > The front brake caliper is tight. > > > Is there anything inside the forks which could loosen and clunk? > > > Thanks. > > > Bob Kaub > > > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > > Post message: DSN_klr650@yahoogroups.com > Subscribe: DSN_klr650-subscribe@yahoogroups.com > Unsubscribe: DSN_klr650-unsubscribe@yahoogroups.com > List owner: DSN_klr650-owner@yahoogroups.com > > Support Dual Sport News by subscribing at: > http://www.dualsportnews.com > > Your use of Yahoo! Groups is subject to http://docs.yahoo.com/info/terms/ >

[Andrus Chesley]

I had this problem and tighten up on the steering head just a touch anyway. Cured the klunk. Andy Chesley Jennings, La. KLR & R11RA

> Saturday I noticed my '98 making this clunking sound when I come to a stop > and the front end does that little rebound as you stop. > Loose head bearings came to mind so I decided to confirm the diagnosis by > lifting the bike on the centerstand and doing the grab and shake the front > forks thing. > Here's where it gets strange. When doing the front fork shake I was

unable

> to detect any looseness in the head bearings at all. I did this test

twice

> several hours apart and could not feel any looseness. > If the head bearings are not loose, then what is making the clunking

sound.

> The front brake caliper is tight. > Is there anything inside the forks which could loosen and clunk? > Thanks. > Bob Kaub

[nvdrifter@yahoo.com]

I am currently looking for motorcylcle magazine articles pertaining to the klr 250 (preferrably from the 1980's- but newer is alright, too). If anyone knows what magazines and what issues they were in, please let me know. Also, if anyone has any old issues with articles about the klr 250- and a scanner- please e-mail me the scanned articles if you can. I would much appreciate any help with this. Thank you. Joe nvdrifter@...