I've seen a few reports of clonking from the front on the GTR so I thought I'd pass on my experience of this as it may help others solve the issue.
My GTR started clonking through the bars when braking after only 5k miles or so from new. You could make it do it by pumping the forks on the brakes at a standstill. You could feel slight movement between the top yoke and the head stock. However no amount of pulling and pushing on the bottom of the forks would show any play. Bike also became very difficult to ride at much below 5 mph or so, no way you could keep it straight.
So off it went back to dealer (DK Motorcycles). They told me it was the head bearings, which they had adjusted. Sure enough the clonk was gone although the low speed stabiltiy didn't seem much better but I decided to live with it.
After another 3k miles or so clonking again. Same deal as before. Out of warranty now so decided to take a look myself. After a bit of investigation and reading the service manual the problem is now solved (I hope):
Firstly the head bearings were too tight not too loose which is why the bike was so hard to ride at slow speed.
Secondly the upper most stem bearing lock ring must be tightened down to the adjuster ring below and the lock washer tabs engaged.
DK tightened the head bearings (way too tight) and mangled the slots in the ring in the process (thanks guys). Amazingly the lock tabs were engaged with the locking ring a good half turn away from the adjuster ring. This means when the top yoke is tightened down on the stem by the centre nut it's just pushing on the loose lock ring. It would appear that it's the top yoke that clonks not the steering stem.
Getting the bearing setting right I found hard to do. The cables and hoses make it difficult to feel how free they are. In the end I backed off the adjuster ring until I could definately feel play at the bottom of the forks and then slowly tightened the ring just far enough to remove the play.
Torquing the stem nut seemed to tighten the bearings too so you have to allow for it.
I have to say it's hard to see how the top yoke can move even if the locking ring is not tghtened down. All I can say is the low speed steering is now normal and there is no clonk no matter how hard you pump the forks.
Sad to say that in over 30 years of motor cycling this was just another example of shoddy dealer maintenance to add to past experiences. Also sad to say that the GTR is the one and only bike I have ever owned with head bearing issues AND it would seem this was an assembly fault from new. I don't know how the bike arrives crated at dealers so can't say if it's a Kawasaki or dealer job.
That's just crap servicing by them.
As a MOT tester the easiest way to test stock bearings is for someone to sit on the bike and put back brake on.
You should then try and roll the front wheel from the top.
You will hear or feel the movement in the headstock bearings if something is wrong
Quote from: futura on July 13, 2012, 11:07:18 PM
Sad to say that in over 30 years of motor cycling this was just another example of shoddy dealer maintenance to add to past experiences. Also sad to say that the GTR is the one and only bike I have ever owned with head bearing issues AND it would seem this was an assembly fault from new. I don't know how the bike arrives crated at dealers so can't say if it's a Kawasaki or dealer job.
I think this last sentence says it all really.
When will Kawasaki ensure that ALL dealers maintenance staff are in receipt of the correct level of training and that they are competent ? Its a basic requirement, surely :ohplease:
BTW :185: futura, nice to have you on board, and thanks for the posting :smiley:
Thanks for that useful post futura.
I'm going to check mine tomorrow, but I don't think I've had that issue. QC these days is an after though.
Yes , good post , one for future ref :clap:
Have this clonk in the front end of mt GTR,not all the time.
Have checked all the bolts and the steering bearing and the triple clamp.
When I was in for my 7500 service,either the mecanic or me could get it to clonk.
but on my way home i had to stop at a roundabout and there it was again.
Seems to appear only when stopping or driving slow and use the brake.
Yup...this is what I had on mine, and i never got to the bottom of it... Bike tis gone now btw.
Wheel bearings.
Put the bike on the centre stand and spin the wheel with the handle bars turned hard left or right.
The mud guard will act as an amplifier, if it sounds smooth your all good but if it sounds a bit grumbly its your bearings.
I should add that I found this out because I had a clonk from the front when ever I rode off a drop kerb at work.
(https://lh6.googleusercontent.com/-o_Ce_SMVkWs/S_QPkDiIRhI/AAAAAAAABHg/tTBS_IgW-9o/s638/DSCF5102.JPG)
I blame jet washing as the gruby bearing is the right hand side.
Which if you think about it is the side most exposed when on the side stand.
You don't fancy doing mine for me do ya? lol I have the same problem and am useless with a spanner....
I had the workshop replace them when the tyres were done.
£42 inc Vat
The wheels were off anyway so why not.