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fork clunk #720661
12/31/17 10:42 pm
12/31/17 10:42 pm
Joined: Nov 2017
Posts: 30
rock hill ny
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dale sonny Offline OP
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rock hill ny
Hey all. I took my forks apart and replaced the bushings, seals, dampener tubes and upper fork tubes. They are back together now and when I compress the suspension it seems ok. But if I pull up on the bars, when the forks top out they clunk. I don't think it did it before I took them apart but I never pulled up on the bars. This is on my 69 Daytona bitsa. Could I have something together wrong? I used 15 wt oil and put in 200cc.

Last edited by dale sonny; 12/31/17 10:43 pm.

69 Daytona/ scrambler
02 BMW r1150r
assorted vintage dirt bike's
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Re: fork clunk [Re: dale sonny] #720663
12/31/17 10:50 pm
12/31/17 10:50 pm
Joined: Dec 2004
Posts: 9,077
Scotland
kommando Online content
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kommando  Online Content
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Scotland
The sleeves between the bushes, did you fit them thick end down ?

Re: fork clunk [Re: dale sonny] #720664
12/31/17 10:54 pm
12/31/17 10:54 pm
Joined: Nov 2017
Posts: 30
rock hill ny
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dale sonny Offline OP
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rock hill ny
Yes I did. By luck, I saw the old ones were that way.


69 Daytona/ scrambler
02 BMW r1150r
assorted vintage dirt bike's
Re: fork clunk [Re: dale sonny] #720669
12/31/17 11:41 pm
12/31/17 11:41 pm
Joined: Dec 2004
Posts: 9,077
Scotland
kommando Online content
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Scotland
Look at your brakeplate and see if the fork leg nub is moving in the brakeplate slot and giving the clunk, if it is then shim the gap.

Re: fork clunk [Re: dale sonny] #720684
01/01/18 1:29 am
01/01/18 1:29 am
Joined: Nov 2017
Posts: 30
rock hill ny
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dale sonny Offline OP
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it only clunks when the forks top out. No noise while compressing the forks.


69 Daytona/ scrambler
02 BMW r1150r
assorted vintage dirt bike's
Re: fork clunk [Re: dale sonny] #720686
01/01/18 1:53 am
01/01/18 1:53 am
Joined: Nov 2008
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Bishop, Calif.
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desco Online content
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It seems to me that the oil works in one direction and the springs work in the other. PJ1 makes fork oil in many weights. Try a heavier weight. I saved a buddy of mine $300 with this suggestion.


1968 T120R
1972 T120RV
Any advice given is without a warranty expressed or implied.
Re: fork clunk [Re: dale sonny] #720688
01/01/18 2:10 am
01/01/18 2:10 am
Joined: Sep 2011
Posts: 944
New Zealand
Excalibur Online content
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New Zealand
As the bike is a bitsa, could springs be 650?
Try heavier weight oil as suggested, it's easiest thing in process of elimination.

Re: fork clunk [Re: Excalibur] #720751
01/01/18 4:46 pm
01/01/18 4:46 pm
Joined: Nov 2017
Posts: 30
rock hill ny
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dale sonny Offline OP
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rock hill ny
The springs are new also. I forgot to put that in the first message. I'll try heavier oil. A guy from a triumph club at VMD told my buddy to use no heavier than 20wt oil. I'll try that. My buddy actually had 50wt oil in his and they still clunked. My old damper tubes were plastic. New ones were alloy. Could that be it?

Last edited by dale sonny; 01/01/18 4:47 pm.

69 Daytona/ scrambler
02 BMW r1150r
assorted vintage dirt bike's
Re: fork clunk [Re: dale sonny] #720867
01/02/18 4:21 pm
01/02/18 4:21 pm
Joined: Feb 2014
Posts: 935
Lancaster, California
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Lancaster, California
My '68 TR6 forks always clunk when I put it on the main stand. I rebuild them twice with the same effect. I stopped worrying about the same stuff and just let it be. I suppose try a thicker oil

Re: fork clunk [Re: dale sonny] #720896
01/02/18 8:08 pm
01/02/18 8:08 pm
Joined: Nov 2017
Posts: 30
rock hill ny
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dale sonny Offline OP
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rock hill ny
I never noticed the clunk while riding. But I haven't ridden since the new fork parts. I did notice it after I rebuilt the forks and jacked it up on my stand. Maybe it was doing it before. My buddy rides a 65 650 off road and his clunk a lot riding the woods.


69 Daytona/ scrambler
02 BMW r1150r
assorted vintage dirt bike's
Re: fork clunk [Re: dale sonny] #720972
01/03/18 7:45 pm
01/03/18 7:45 pm
Joined: Feb 2014
Posts: 935
Lancaster, California
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Lancaster, California
I'm curious to know the "real" reason why the forks clunk. I keep hearing about the sleeves ordeal but that didn't fix my problems.. Is it the nature of the forks?

Re: fork clunk [Re: dale sonny] #720980
01/03/18 9:05 pm
01/03/18 9:05 pm
Joined: Apr 2005
Posts: 1,611
Mississauga, Ontario.
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Adam M. Online content
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Mississauga, Ontario.
When sleeves are installed incorrectly they give much more than a clunk smile.
Clunk is normal with these forks when they extent to max length - the lack one spring to dampen it.
71 and up forks have it and no more clunk you can here from them.


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