2009 ZX-6R Loud Front End Clunk Over Bumps - ZX6R Forum
 6Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 41 Old 02-08-2013, 06:55 PM Thread Starter
Squid
 
Kruz's Avatar
 
Join Date: Feb 2013
Location: Dallas
Posts: 38
2009 ZX-6R Loud Front End Clunk Over Bumps

My '09 6R has about 7000 miles and has had a distinct clunk in the front end since almost new. Seems to be getting louder. Steering head bearings are adjusted to spec.

It occurs at speeds as low as five to ten mph when riding over a sharp drop off or rail road track, even one inch drop and it clunks. If I approach it a litte fast and squeeze the front brake the noise is almost gone. The Ohlins damper makes a seperate clacking sound but this is different. Floating brake rotor or maybe the BPF front fork? Anyone else experiencing this sound?
Kruz is offline  
Sponsored Links
Advertisement
 
post #2 of 41 Old 02-08-2013, 09:32 PM
World Superbike Champion
 
zxrider432's Avatar
 
Join Date: Dec 2012
Location: Dutchess, ny
Posts: 2,476

I Ride: 2004 ZX6R trackbike , 2013 Zed Ex 10r, 2012 R6 trackbike , 2015 Zx6r, 2005 Zx6r.
i have the sound on my 04.. but i know it is my steering stem bearing

Fuck liberal cunts. ..
zxrider432 is offline  
post #3 of 41 Old 02-08-2013, 09:34 PM
ZX6r.com Supporting Member
 
Magoogle's Avatar
 
Join Date: Mar 2012
Location: centreville, VA
Posts: 1,760

I Ride: 2006 ZX6RR
happened to me.. My front fender was loose lol.

Zoey: 2006 ZX6RR = Kawi Race ECU - Bazzaz QS4 - Vortex Rear-sets - Vortex Sprockets - Vortex Clipons - Battlax S20's - Penske Rear Shock - M4 Headers - The2Wheel Shorty Clutch/Brake - EK Green X-Chain - K&N Filter - Rockford Fosgate Speaker System - RS-5 Carbon Slip-on.

Anyone in the VA/DC/MD Area need electronics added to your bike? Hit me up on facebook or PM me here! From LEDs to USB and anything else you can think of.
Welding and fabricating services also available.
Facebook: David (Magoogle)
Skype: Davey_Cave
Magoogle is offline  
Sponsored Links
Advertisement
 
post #4 of 41 Old 02-08-2013, 09:43 PM
World Superbike Champion
 
zxrider432's Avatar
 
Join Date: Dec 2012
Location: Dutchess, ny
Posts: 2,476

I Ride: 2004 ZX6R trackbike , 2013 Zed Ex 10r, 2012 R6 trackbike , 2015 Zx6r, 2005 Zx6r.
mine is more a creek. not a clunk or a bunk or spunk... well if spunk was on my bike i need to find out who is doing it

Fuck liberal cunts. ..
zxrider432 is offline  
post #5 of 41 Old 02-08-2013, 09:44 PM
Post Master General
 
trackdayhero's Avatar
 
Join Date: Feb 2012
Location: il
Posts: 7,313
I'm not sure what the problem is but I can tell you how to stop it from happening. Don't ride over bumps.
Scorpi0 likes this.

.
trackdayhero is online now  
post #6 of 41 Old 02-08-2013, 09:50 PM Thread Starter
Squid
 
Kruz's Avatar
 
Join Date: Feb 2013
Location: Dallas
Posts: 38
It's not the front fender, checked that already and all the front fairings and instrument cluster feel tight.

These bikes have semi-floating front rotors but I've never seen one make this kind of racket before.
Kruz is offline  
post #7 of 41 Old 02-09-2013, 01:10 AM
World Superbike Racer
 
09ZX-6R's Avatar
 
Join Date: Oct 2009
Location: Spokane WA
Posts: 1,362

I Ride: 2010 ZX-6R
ok...i have a few questions?

1. do you like to do wheelies, stoppies, or hard braking?
2. has it ever been layed down?
3. when was the last time you checked your brakes?
4. does it do it all the time?
5. if i got on it, would i be able to replicate and notice it?

few things to consider...IF its front end...

1. rotor retainer rivets are beyond spec- causing the rotor to "pop" when brakes are initially applied, and under heavy bump loads...

2. brake caliper mounting bolts torqued to spec...if not the claiper could be moving...

3. wheel bearings have gone bad...rare, but does happen...

4. steering stem bearings loose...tho they can be at spec, they can still be wrong if not done correctly...the manual does not tell you to torque them with the front end unloaded..

5. are the fork clamps (upper and lower) torqued properly...they could be moving up and down in the clamps...

6. has the fork oil been changed yet

7. fork bushings (inner and outer guide) may be out of spec...need to replace them...if so, replace the dust cap, fork seal, retainer clip, and both bushings...on each fork leg...to check this, unload the front and pull and push the wheel in and out...

8. are your clip-ons (handle bars) torqued properly..they could be moving as well...

to check most of this, the best method is to suspend the front of the bike by the frame, NOT THE NECK, and check the front end for all the listed things... 1 of them is bound to be the issue...to do that, pop out the two frame plugs and put in a tie down in each hole, then hang the bike from a frame or beam of some type...you only need 2 inches of ground clearance...

hope this helps...if none of the item is listed work, the you have a rear end issue that may be resonating thru the frame making it feel like the front end is clunking...these methods are what we use in the K-tech program here at MMI...and i also use it at the track when tuning suspension for people...

2010 ZX6R-Ti Valves-Billet deg.cams-MPQT Throttle-Type A&C Trans-Bazzaz ZFi-QS-TC-Ign.Mod.-M4(full) exhaust-MBR AMA Engine-BMC Race filter-SMEv3-SpeedoDRD-STPS mod-Magnesium Wheels-R10 type 3-RK gold-15f/16f w/42r,44r,45r spkts.-ohlins 25mm forks, ohlins TTX36 Markll shock- brembo ft/rr Mstr. cyl-SS lines-Vesrah Sinterd pads-galpher wave ft/rr rotors-alumalite tripple clamps-custom paint-tank foam-tecspec pads-VDS mod-Manual dual fan-Radiator guard-keyless ign.-dual mapped.

BMW Motorrad, Suzuki Gold, Kawasaki, Triumph, Polaris/Victory, Can-Am, Sea Doo, Ski Doo,& Spyder Certified Technician !!! and KTM qualified Technician.
09ZX-6R is offline  
post #8 of 41 Old 02-09-2013, 01:55 AM
MotoGP Champion
 
Street Hawk1's Avatar
 
Join Date: Mar 2011
Location: Maryland (My name is Bob)
Posts: 5,012

I Ride: 09 ME ZX6R
I've heard it on my 09 bike. It doesn't do it all the time. Actually, I havent heard it in a while. I do know the sound Kruz is talking about and I'm not sure what it is either. I've searched for this noise with no luck. I thought it sounded like the brake pad shifting when the brake was applied. It definitely sounds like its coming from the front.
I think the only fix for this is a louder exhaust.

Ride GREEN or don't ride at all.
Street Hawk1 is offline  
post #9 of 41 Old 02-09-2013, 09:34 AM
World Superbike Racer
 
Square's Avatar
 
Join Date: Oct 2012
Location: San Jose, CA
Posts: 1,123

I Ride: 2012 zx6
+1 on hearing that kinda sounds like the intake right there loose or smacking something it's like a hallow sound correct?
RJ2112 likes this.
Square is offline  
post #10 of 41 Old 02-09-2013, 09:38 AM
Track Star
 
austexjg's Avatar
 
Join Date: Jun 2012
Location: Central Texas
Posts: 515

I Ride: '09 ZX6R Green/Black
Try looking at the ram air duct bolts on either side - mine were loose and caused similar sound.
RJ2112 likes this.

Anyone can go fast in a straight line...
Better to ride a slow bike fast than a fast bike slow.
austexjg is offline  
post #11 of 41 Old 02-09-2013, 09:58 AM
MotoGP Champion
 
Street Hawk1's Avatar
 
Join Date: Mar 2011
Location: Maryland (My name is Bob)
Posts: 5,012

I Ride: 09 ME ZX6R
It could be a hollowish sound. It's been a while. Ill check my intake today.

Ride GREEN or don't ride at all.
Street Hawk1 is offline  
post #12 of 41 Old 03-07-2013, 07:20 AM Thread Starter
Squid
 
Kruz's Avatar
 
Join Date: Feb 2013
Location: Dallas
Posts: 38
Well even though I was pretty sure it wasn't loose, I did my steering head bearings over the weekend. The steering stem head nut (big 37mm job above the upper clamp) was not on spec (book spec 58 lb-ft) felt more like about 20-25 lb-ft. When I removed the upper clamp, the steering stem lock nut was finger tight which gave me some hope I was on to something and the steering stem adjusting nut needed about 1/8 turn to bring it up to the 15 lb-ft torque specified in the manual. So my steering head bearings were definitely a little on the loose side.

I carefully put everything back to book torque specs and went for a test ride. Leaving my driveway, first bump....clunk...the little bastiche is still there. On a more positive note the front end did seem overall to be quieter as there seemed to be several sources of noise that are now gone, just the hollow clunk over the 1" dropoffs remains.

I then went after the ram air ducts. Whoever designed this stuff used the absolute minimum of those cheap plastic pop rivets to secure the inner ram air shroud. I noticed that where the shroud rests on top of the radiator on the left side you could lift the shroud and release it and it buzzed pretty bad. I went through the entire shroud and used electricians tape and that adhesive backed cowl pad foam to eliminate any chafe points and prevent buzzing of the duct work. I did find one plastic rivet had popped loose and retightened that.

Bottom line the bike sounds much better now when hitting bumps ....but the clunk is still there.

Brake rotors appear to be solid as in almost zero float and my brake calipers are torqued right on spec. When I had it up in the air I checked the wheel bearings, appear to be tight and smooth.

I am now about 90% sure it is coming from inside my front fork. The BPF front fork on the '09 and after ZX-6Rs uses a long top out spring, maybe that's rattling...IDK at this point.


Anyone else found anything?

2011 ZX-10R
2009 ZX-6R
2007 CBR1000RR
2006 ZX-14R
2004 VTX1300C

"We walk by faith and not by sight"
2 Cor 5:7

Last edited by Kruz; 03-07-2013 at 11:22 AM.
Kruz is offline  
post #13 of 41 Old 03-07-2013, 09:10 AM
MotoGP Champion
 
Street Hawk1's Avatar
 
Join Date: Mar 2011
Location: Maryland (My name is Bob)
Posts: 5,012

I Ride: 09 ME ZX6R
I forgot to post back but mt intake area was a little loose but not sure if that fixed my sound yet.

Ride GREEN or don't ride at all.
Street Hawk1 is offline  
post #14 of 41 Old 03-07-2013, 11:18 AM Thread Starter
Squid
 
Kruz's Avatar
 
Join Date: Feb 2013
Location: Dallas
Posts: 38
Yep, Kawasaki must have assigned a bunch of newbie engineers to the design team on this bike. It is dynamically a great machine but it has just felt loose and rattly over the bumps since day one. The duct work looks like an afterthought. I'm going to keep looking until I find this, eliminate one thing at a time.

2011 ZX-10R
2009 ZX-6R
2007 CBR1000RR
2006 ZX-14R
2004 VTX1300C

"We walk by faith and not by sight"
2 Cor 5:7

Last edited by Kruz; 03-07-2013 at 11:22 AM.
Kruz is offline  
post #15 of 41 Old 03-07-2013, 11:24 AM Thread Starter
Squid
 
Kruz's Avatar
 
Join Date: Feb 2013
Location: Dallas
Posts: 38
Quote:
1. do you like to do wheelies, stoppies, or hard braking?
2. has it ever been layed down?
3. when was the last time you checked your brakes?
4. does it do it all the time?
5. if i got on it, would i be able to replicate and notice it?
No
No
Last Weekend
Yes
Yes

2011 ZX-10R
2009 ZX-6R
2007 CBR1000RR
2006 ZX-14R
2004 VTX1300C

"We walk by faith and not by sight"
2 Cor 5:7
Kruz is offline  
Reply

  ZX6R Forum > ZX6R Forum > The ZX6R


Search tags for this page
03 zx6r front end noise
,
2013 kawasaki 636 front end clunking
,
chain is making a popping sound.at low speed on my zx 636
,

clunk noise from front zx6r

,

kawasaki zx14r front end clunk

,
tightening steering stem zx6r
,

zx14r loose steering

,
zx6r rattle over bumps
,
zx6r steering head fall away test
,
zx6r steering stem click
,
zx7r clunk over bumps coming from front forks
,

zx7r front end popping

Click on a term to search for related topics.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
click from front end on light braking BadAssRX-7 The ZX6R 15 12-22-2016 04:27 PM
Suspension Setup Guide jamboy Guides 9 05-23-2012 02:12 PM
front end vibration califab The ZX6R 16 10-31-2009 06:54 AM
Suspension Settings 2007 ZX6R 210lb Rider flopalock The ZX6R 9 09-26-2009 03:27 PM
Front end shake at speed Drunkula The ZX6R 22 08-28-2009 01:27 AM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome