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Old 5th September 2008
RcRacer's Avatar
RcRacer RcRacer is offline
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Sportster/Buell Model: xls 1000
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Default Fixed the clunky front caliper noise ....

Thanks to a few posts I found in these forums, I tried a solution based the posts. After a week of commuting to work, I can tell you - It works!

Ever since I put the bike together from a frame off rebuild, I have had a very audible clunk in the front calipers as I grab the front brake lever. When I grab the brake very lightly, sometimes it would rattle and then stop as I put more pressure on the brake. The first time I heard it, it scare dthe $h1t out of me but eventually I discovered where the noise was coming from and could even see the caliper movement and the corresponding "clunk" when I rocked the bike at a stop light.

Here's what I did. I removed the calipers and checked the bolts and lower fork bushings. The bolts were slightly worn but the bushings were fine. The holes in th calipers had a little more play than the bushings and probably contibute to most of the movement of the caliper. I installed the calipers with new bolts but I added a small piece of weather stripping between fork and the caliper at the top bolt. ( Glued to the fork ) There is just enough pressure there to dampen the movement but it is still free to move as designed.

The result is quite front brakes! Hopefully, if any of you have the same problem, you can use this simple fix to reduce the noise from the caliper.
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Old 5th September 2008
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Yup done that to both frt and rear Calipers on my 81 Just have to replace the stripping every once and a while after it packs down abit.
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Old 5th September 2008
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part number 44125-82, foam tape, used on 1982, 1983 XL, XLS, XLX
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