Fixed the Clonk plus Clutch kit

[Bones]

Ever since I've owned my bike it's always made a clonking sound in the front end somewhere dropping off driveways, speed bumps, potholes etc... so I decieded once and for all to find out what was causing it. The forks have been totally rebuilt so I knew it wasn't them, all the fairing and guage mounts are ok, head stem bearings have been adjusted, so that just left the headlight.



After pulling the headlight out and inspecting it, I noticed if you grabbed the bulb assembly and wriggled it, the whole inner lens would move inside the case and rattle a bit. Aha... now how to fix it?.
There's little clips that hold the glass on, but removing them and trying to lever off the lens only resulted in breaking little shards of glass off, so I decieded to glue it instead.

Inside the bottom right of the light you'll see a white round plastic fitting with a rod, the lens was moving on the plastic piece so i got some Super Glue and reached in and put some on it and let it set.



Success, nice and tight, only problem was I put too much glue on and a bit dropped down onto the inner glass,   but I managed to get most of it off with a long screw driver and some rag.

All back together for a test ride and now I noticed the clutch felt funny, loud clonk into gear, takeoff with the lever just off the bar and hard to find neutral. Checked the slave for leaks, nothing there, bled it, felt better but same symptoms, so new Master kit ordered.

Randy has them for $25.96, the local dealer here $77.00.   Needed it so rang up and ordered it then and there, but looking on Ebay that night saw a complete 2006 XJR Clutch Master with lines for $66.00 free postage. Doesn't that shit ya, but anyway, new kit installed and all is good again in the clutch department, plus NO clonks from the front end.

[ribbert]

Ever since I've owned my bike it's always made a clonking sound in the front end somewhere ........

Excellent work on finding the clunk Tony, I've never gone looking for it but I do have it. I will add it to my list. Well done!

Now, if you could just find a fix for the PVC spacer clunk in the forks........

Don't beat yourself up too badly about the local price of the M/C kit. The landed price of the RPM unit is about double it's listed price AU (exchange rate and freight)  Still cheaper but it doesn't hurt as much if you take that into account.

Anyway, if it gets you back on the road sooner, who cares.

I assume this is all part of your rally preparations so the bike will be good to go for the next one.

Noel

[biggo]

Like your glue fix on headlight.
I stopped mine rattling some time back cut some high density foam and squeezed it between reflector and outer casing. This plus filling my mirrors with silicon and re valving and springing my forks has my front end silent now

[yamaha fj rider]

Great fix. Thanks for posting. This is now on my to do list.

Kurt