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Rattle From Front Forks?

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Big Daddy

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Discussion starter · #1 ·
I’ve had a rattle coming from the front end that has been haunting me for weeks. I find nothing loose at all. It is not engine related. Bumps and vibration exacerbate the rattle while in motion.

With that said, I went out tonight to try to listen closely for the source and found nothing. BUT, when I got home and searched again for loose parts, I found a leaking left fork seal. It had not leaked before tonight.

Obviously, I need to fix the forks. However, do any of you think the two are related? Would the fork innards make a rattle if they were going bad, or do I still have a mystery rattle?

Thanks in advance!
 
Discussion starter · #3 ·
btk572 said:
headlight or something in the head light ? possibly calipers or loose/worn fender bushings, btk572
Click to expand...

Thanks, btk572. Headlight is sound. Inside? Hmmm? I’ll have to check. The calipers and fender were the first places I went, because that’s where the sound seems to be coming from. These areas check out okay. I still find it oddly coincidental that the fork started leaking too. :confused:
 
#6 ·
Do you notice if it goes away with front brake apply? There have been many cases over the years of brake pads rattling around in the caliper frames. If this is the case, you can take out the tension springs, which is the flat piece of stainless steel mounted on the same pin your brake pads are held in by. Take that out, and give it a slight tweak to increase the tension on the pads. I had to do this with mine shortly after I bought it.
 
Discussion starter · #7 ·
yamaweezle said:
Do you notice if it goes away with front brake apply? There have been many cases over the years of brake pads rattling around in the caliper frames. If this is the case, you can take out the tension springs, which is the flat piece of stainless steel mounted on the same pin your brake pads are held in by. Take that out, and give it a slight tweak to increase the tension on the pads. I had to do this with mine shortly after I bought it.
Click to expand...
No. I did not think to listen for that difference. However, I’m pretty sure braking did not affect the rattle. The rattle is loud enough to be heard over a very loud open-pipe exhaust when at low speeds. Interesting, though. I’ll have to check that out. Unfortunately, I’ll have to fix my forks first so I can ride it. Thank you for the great advice!
 
#12 · (Edited)
Not knowing if you have a fork seal leak, I'll throw this out there. I don't know if the front suspension preload has been adjusted but in case helpful . . . I noticed that when I adjusted the front end all-the-way to the last line (Line 1) the springs made noise inside the fork tubes under compression. I backed-it-off so two lines are visible and both forks went quiet again. Here's the old link: > http://www.rswarrior.com/forums/11-...equently-asked-warrior-questions/158950-how-lower-2006-warrior.html#post2069381

For visual info check service manual page 3-53 (adjusting forks) and the owners manual also has the same helpful graphic (in section 4).

Separate from this, some have discovered the noise is actually coming from the front brake calipers. The brake pad springs could be weakened or missing so the pads rattle. Way back there might have been one member who had a loose front axle and the wheel spacer was rattling sometimes, but that doesn't seem to be common (at least I don't recall seeing it again around this joint).

SURFANDJET said:
What was the result? Was it the forks? I have the same issue. Can find it. Forks are the only thing unchecked and that I don't know much about.
Click to expand...
 
#13 ·
Thanks ArizonaWarrior. I'm anxious to get home and try this. From what I can recall, I believe that they are adjusted all the way down (Line 1). I haven't touched the forks, and bought the bike used so I can't speak for him. I didn't realize those were adjustments. They looked like bolts that held the suspension together. I'll post the results. Sure hope this works. That rattle drives me nuts.
 
#17 · (Edited)
#18 ·
Hmmmmm. Interesting. I've had the same ping nice from time to time. Sounded like something tapping my front fender when I hit a nice bump. Just checked the preload adjustment they had 4 or 5 lines sticking out. Haven't really noticed it happening after I took the front fender off. But then again I haven't hit any good bumps lately either. Is there a time frame or mileage when the fork seals could start going bad? I have an 2006 with 14k miles. I wouldn't think the seals would be going bad so soon.
M
 
Discussion starter · #19 ·
MMFB said:
Hmmmmm. Interesting. I've had the same ping nice from time to time. Sounded like something tapping my front fender when I hit a nice bump. Just checked the preload adjustment they had 4 or 5 lines sticking out. Haven't really noticed it happening after I took the front fender off. But then again I haven't hit any good bumps lately either. Is there a time frame or mileage when the fork seals could start going bad? I have an 2006 with 14k miles. I wouldn't think the seals would be going bad so soon.
M
Click to expand...

The ones on my 2006 went at 26k.
 
#20 ·
Big Daddy said:
The ones on my 2006 went at 26k.
Click to expand...
Everything about my forks are stock from 05 with no leaks so far. I did change the fluid when i installed the 2" extensions for the Mortons 7 degree trees, but that is all i did to them. I have about 64,000 miles on the forks with no problems to date.
 
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