ZX10R 2008 strange clunk from the front end - Kawasaki Forum :: KawasakiWorld.com
 
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post #1 of 10 Old 01-02-2016, 12:32 AM Thread Starter
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ZX10R 2008 strange clunk from the front end

Happy New Year everyone!!!

I have recently became an owner of 2008 zx10r with only 16000 km on the clock. The bike is in a new condidtion but...
When I test rode it I noticed the clunk in front suspension/front end. It was present even on small road bumps. I checked the steering stem bearing nuts and they were completly loose, so I figured out it was the reason. Unfortunately after bearing adjustmen the annoying clunk is still there.
It doesnt come from the calipers or brake pads because when the brake is engaged there is absolutely no difference in the sound. It also has nothing to do with the forks. When I lock the front wheel againt a wall and squeeze front suspension it works smooth and quiet. The clunk seems to be located somewhere on the left side. I can literally feel it in my left handlebar.
And the last, perhaps important clue: when I ride the bike before engine is fully warmed up, there is absolutely no clunk what so ever. Smooth as a butter. Once it warms up the clunk is back. And for sure its not related to the engine itsself- I tested it on a bumpy downhill with engine off and had the same sounds.
Another thing- I am not able to reproduce this sound when the bike is not moving. It is mostly noticeable at slow speeds.

Please give me your ideas
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post #2 of 10 Old 01-02-2016, 07:05 PM
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I had something similar on my ZX12R. There was a clunk from the buttons and also the design on original discs are such that they might warp and when your bike is cold the discs are cold but as you ride they rub a little if they have a little warp and they heat at the same time making the warp worse. Clunk from the buttons is nothing to be worried about and this is very common and it is not really a fault. But traditional discs can develop a warp very easy because the heat expansion has nowhere to go and the disc gets warped and worse when it heats up. If you can feel it in your handle bar and it is getting worse when the bike warms up that is most likely the reason.

I would recommend EBC Floating MC Rotors and EPFA Sintered Fast Street and Trackday Pads. Don't use these pads for rear. For rear use Double-H™ Sintered Superbike Brake Pads they have more feel.

Here is a link if you are interested.

Floating MC Rotors - EBC Brakes

Just remember if you are going to get new discs you can't use old pads. Also new discs need to run in so don't ask of them too much too soon. Some material from the pads has to transfer to the disks before the brakes start to work. If you ask too much too soon two things will happen. One you won't have good braking power. Two you will overheat and warp the discs and destroy them.
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post #3 of 10 Old 01-03-2016, 05:22 AM Thread Starter
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Here is a short clip of the noise. I do believe its fork related.
http://vid1381.photobucket.com/album...pswiw6pzg6.mp4

Last edited by pawciorc; 01-03-2016 at 05:51 AM.
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post #4 of 10 Old 01-03-2016, 06:13 AM
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Quote:
Originally Posted by pawciorc View Post
Here is a short clip of the noise. I do believe its fork related.
http://vid1381.photobucket.com/album...pswiw6pzg6.mp4
You had the front brake locked on all the time? If so it should lock all the component. The disc, caliper and the brake pads. But if you have a look the disc moves back and forward inside the caliper. It don't feel right. Could it be that you don't have brake pressure on the left hand side? If you didn't have brakes on do it again but this time lock the brakes. Then it should take all the possible movement out of the disk, pads and calibre. If you still have a problem it is the forks but if the noise is gone it is the brakes. Maybe you have a stuck piston or one of the circuits on the brakes don't work. I'm not sure it the front is one or two circuits like on cars. If one fails you still have one.
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post #5 of 10 Old 01-03-2016, 06:18 AM
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It might be hard to spot but I use 55" as a monitor. The disc moves inside the calibre. I'm pretty sure that has something to do with the brakes. 16k should indicate that it still has the original pads in it. But just in case check if the pads have been changed for road worthy. Just maybe some parts are missing like backing plate with a spring to keep the pads from moving. I haven't pulled one of those apart so I'm just guessing.

Last edited by puppeli; 01-03-2016 at 06:35 AM.
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post #6 of 10 Old 01-03-2016, 06:36 AM Thread Starter
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The front brake was not engaged. I used rear one and my weight to push the front end
Besides I am pretty sure it is not brakes related. The sound remains the same when I engage front brake while going through road bumps.

Last edited by pawciorc; 01-03-2016 at 07:53 AM.
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post #7 of 10 Old 01-03-2016, 12:00 PM Thread Starter
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Originally Posted by puppeli View Post
You had the front brake locked on all the time? If so it should lock all the component. The disc, caliper and the brake pads. But if you have a look the disc moves back and forward inside the caliper. It don't feel right. Could it be that you don't have brake pressure on the left hand side? If you didn't have brakes on do it again but this time lock the brakes. Then it should take all the possible movement out of the disk, pads and calibre. If you still have a problem it is the forks but if the noise is gone it is the brakes. Maybe you have a stuck piston or one of the circuits on the brakes don't work. I'm not sure it the front is one or two circuits like on cars. If one fails you still have one.
The discs themself have a slight play on the hollow rivets, so when I engage front break to work on the suspension the discs make some noise. That is why I did not use the front brakes for the clip I posted
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post #8 of 10 Old 01-03-2016, 03:53 PM
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Check the routing of the brake hose ... especially as it goes through the mudguard mount and passes the bodywork. For instance try the bounce experiment with the mudguard clip removed. [My old GPZ had a similar clunk that was the hose routing mount not fully homed.]
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post #9 of 10 Old 01-06-2016, 05:38 AM Thread Starter
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I have ordered a set of steering stem bearings and will start with it.
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post #10 of 10 Old 01-12-2016, 09:24 AM Thread Starter
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Ebay idiot sent wrong bearings :( But the stock ones were in perfect condidtion. I told the mechanic to clean them and re-grease. After that simple labour I have a completly new bike. Thank you all for ideas and help.

Case closed :D
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