Hey All, Need to reach out to the forum for some help with a FL fork assembly issue.
Here is the issue; when ever you hit a bump or clamp on the front brake, there is an initial light clunk thats driving me nuts.
The forks are set up with racetech gold valves and springs, the ride is finally the best its been since the bike was new and Ive tried the progressive monotubes, which is when the clunking was first noticed, looking back I had the lower legs powder coated and I think after a week of being apart I may have installed the lower stop in the wrong position, this is the only thing that seems that could be causing this to happen.
I have talked with racetech and the dealer tech and have gotten conflicting information, so here is my question. The book shows the lower stop or oil stop (per service manual/parts manual) in the bottom of the fork leg. The books are not clear to me, but does anyone know if the stop goes on the bottom of the dampener tube or does it fit into the same shape tapered hole in the bottom of the upper fork leg???
The dealer says the dampener tube bottom and R/T says it is correct to be in the hole in the bottom of the upper fork leg.
Thanks for all professional opinions.

 

bump!

 

For what it's worth...my 09 does the same thing you are describing, and the front end has never been disassembled. It's done it for about 15K miles now. Never gotten any worse, or manifested into any other type of problem. I worried about it for a while...but have put it out of my mind for now...until I do wheels and chrome front end.

 

Have you checked the headset also?

Sounds like you still have some questions in your head about something being right internally. When I have that feeling it drives me nuts until I take it apart and figure it out.