FE/FC 4cs knocking noise...help

There is a recall on the '15 4cs forks...I believe it is from the fork caps not being tightened to the piston rod. It is not supposed to affect the USA models.

So, the forks are the USA model and as new. When applying the front brakes and compressing the forks, there is knocking noise. I thought at first it was a loose steering stem (which is what it kinda sounded like), then some wiring under the headlight hitting the plastic, but finally traced it down to the forks.

I took them off and compressed them onto the carpet and sure enough, they make a clunking noise when transitioning from up to down movement.

This will happen at the very top of the stoke cycle as well as mid. I would compress them half way and then move them back and forth and you could here some sort of knocking noise in them...it sounded like up toward the top, but its hard to tell. And then they would make the same noise from fully extended to being compressed.

Does anyone have the 4cs forks they could hold the front brake on and push the fork and see if there is a clunking or knocking noise on the up to down transition.

The recall said the knocking started around a couple hours. These forks are as new, so they shouldn't have even had time to have any problems yet.

Thanks in advance.

They will make a soft clicking noise which is normal. If it's knocking loud I'd say that's not good.

Hmmm...it is kind of a clicking noise. I had another guy look at it and he thought it was probably normal. He thought it may be the adjuster rod that goes inside the damper rod moving up and down or possibly the fluid making clicking noises as it moved from chamber to chamber.

After taking the forks off and bringing them inside and compressing them with my ear close by, it possibly may be originating where the lower fork leg goes into the upper fork where the seals are...but its really hard to pinpoint a noise.

If they are new have your dealer open them up to verify.

In OEM configuration mine made clicking noises. Sounded to me like fork spring gap like they were not having any preload and were rattling around. This was prior to my ZipTy/(Procircuit/ESR) mod.......and guess what, they still do make a clicking noise when bouncing the forks, not quite a loud as before the reconfigure mod but they still do.
I thought at the beginning there was a loose something, like spring gap- but when they went into service and came back with the same clicking noise (but not quite as loud) I just left it alone, it is what it is.
Do I really want to know exactly what it is---YES I do...but as long as everything is working as well it does I have relented and don't give a hoot. Cant hear it when on the gas anyway!! F it, make sure everything is tight and ride the crap out of it.

Jeremy Wilke told me exactly what the noise actually is but my limited comprehension and poor memory leaves me blank...lol. he said it is normal in stock form but since having the 4cs asymmetrical system installed, they are quiet now.

That's all good to know. Took the left fork off and it clicks a little but not as bad as the right fork. But, you can hear the spring hit the sides of the left fork if you shake it back and forth, but cant hear the spring in the right side under the same scenario.

If this is normal, I'm gonna just ride it until next year when they are do for an oil change and then have them upgraded by Zipty.

MX-Tech silenced the 4CS demons !

Just install a louder pipe and ride it! Or earplugs work well. My buddy rides a ktm 350 and says since wearing ear plugs his bike gained 10 MPH on the highway...lol

Howdy, all! Just bought a new '15 TE300 and can't wait to ride the thing. I have exactly the same noise and thought all the same things as the folks above and I'm still equally in the dark. One thing I did notice is that the clicking varies with damping: more damping = less clicking and vise versa. I can get the clicking to completely disappear by cranking the damping all the way up. Whether that's how I want to ride or not remains to be seen.

It seems like this has nothing to do with the recall though - is that correct?