I've been having a problem with the front end clunk for several months. I took the bike to the HD dealer and had the new steering stem nut washer installed. They didn't do the fall away check, just changed the washer. It didn't fix the clunk. I am tired of hearing it and I'm afraid something's going to be damaged. So....

I bought a motorcycle jack today and I want to do the fall away check and adjust the star nut to tighten things up. Two questions.... I don't have the adapters for the Dyna. What do you use to jack yours if you don't have the adaptors? I have the service manual and I've read the procedure for the fall away check/adjustment. Are there any tips/techniques that would come in handy before I get started? I'm a little nervous about taking the upper triple tree loose to get in there and adjust.

 

A lot of people use 2X4s. I think if you use them on the front and left rear you should be about right. Don't let the clamp bother you, it's pretty easy.

 

I got rid of the clunk after reading my service manual, something that will spell out the fall away test. Anyways when you go to tighten the stem nut, loosen only the lower triple clamp (triple tree) bolts, tap the clamp areas with a rubber mallet or a deadfall hammer to loosen the fork tubes in the lower tree. Think about what is happening, you are ever pulling the upper and lower trees together so minutely but it happens, tighten the stem bolt and retorque the lower pinch bolts. Mine were 25-30 ft.lbs. (39 mm tubes).

 

i use 3 2x4s, one 1xfor the right rear, i threw away the adapters,the 2xs where alot steadier.

 

Thanks for the help. I hope to get this adjusted tomorrow. One more question. The service manual mentions making some kind of tool that sits in front of the fender with a pointer so you can gauge where the front end "falls away." Does anyone use anything for that or just guesstimate the dimension where it falls away?

 

I rigged up a 2x4 that sat flat on the ground with another piece of wood attached vertically. Kind of like an upside down T and then just taped a pen to the top of that for a pointer. I used masking tape on the tip of the fender to mark the spots it falls away on either side then measure. The manual is a little confusing and isn't too clear on this.

 

Why didn't the dealer do the fall away check?

The instructions in the kit clearly state for it to be done.

 

I don't know why they didn't do it. I had found the service bulletin on this forum and took it to the dealer. They couldn't find that one until I told them the number. The bike was only back there for a few minutes so I'm confident that they only changed out the washer. The clunk was still the same when I got back on to ride home. I should have took it back in and asked but I didn't. Looking back on it, I didn't tell them I had the clunk problem. I had read here that the washer would fix the clunk so I told them I wanted the new washer. I really didn't provide them with enough information. But....the service bulletin does say to adjust so they should have done it anyway.

 

I have a 03 WG and was absolutely, positively, without any doubt SURE that I had the clunk you mention. I did the fall away, new washer kit etc. Same clunk.

This forum suggested tightening the fuel tank bolts-it did the trick-no clunk. Just a thought.

 

Changing the washer alone didn't fix my clunk. After setting proper fall away the clunk went away. The whole process is alot easier than it sounds, just take your time. I made my pointer the same way as JerseyDevil.