CG 125 Front suspension issue, not again!?!!

[Cyclingbiker]

Hi all I am having yet another persistent problem with my ever-breaking-down CG.

This time it is an ever present knock or tap when I go over potholes or speed humps. It's coming from the front somewhere but I can't pin it down really as it only occurs when I'm moving.

I suspected the headset bearings a few weeks ago and last weekend I stripped the whole front end of the bike down and replaced the bearings with some new tapered roller bearings from "Pyramid Parts". The old ones were also taper rollers which surprised me a bit as I was expecting loose ball bearings to fall out. Anyways I changed the bearings and also changed the fork oil while I was at it, twas a lovely mauve/white colour when it came out too, and put the recommended 85cc of 10w suspension fluid back in each.

The knock is still there, the lock ring is tightened as far as possible without making the yokes too hard to turn. No noticeable play is present when messing about depressing the forks when rocking back and forth stood still. There some type of knock audible from the left fork leg so I assume it may be related. Damper assembly maybe?

Some help would me appreciated
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Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[tomh]

I had a similar problem with my 2001 CG but never dealt with it. It was the peice of metal that sticks out in the left fork leg for the brake had worn or was the wrong size (Original wheel but not original forks).

This meant there was a bit of movement on the brake plate. If you press the front brake and move the bike backwards then forwards you would be able to see it move.

I bodged it with a feeler gauge for a week until that fell out.

[Cyclingbiker]

[27cows]

I had this with a CG (drum brake model). In the end I bodged it by wrapping PTFE tape round the bit of fork that engages in the drum plate to take up the slack. Worked like a charm.
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The RXS100: vehicle of choice for Chuck Norris

[blurredman]

[Cyclingbiker]

[Cyclingbiker]

I have since wrapped the lug with a few layers of black electrical tape to provide a better fit for the slot in the brake plate. Unfortunately the knock and the corresponding vibrations through the bars still persist

The Haynes is most unhelpful, only suggesting that "Slack steering head bearings" or "Worn fork bushes" are the two possible causes of juddering when the front brake is applied. The symptom is not exactly what I experience, it mostly happens going over potholes or uneven surfaces with or without brakes applied but is more pronounced under braking. The two possible causes don't add up in my case, the former has been ruled out as they have been recently replaced and the second is irrelevant as the CG is not fitted with fork bushes.

Part of me suspects worn wheel bearings as a possible cause. Ideally I need someone to hold the bike firm whilst I check for play in the bearings to make sure.
____________________
Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[Mark65]

Have you tried looking at the clocks, namely the mounts, jam some cloth under them( from the riders side) and try the bumps again.

Mark
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07 Yamaha YBR125, 07 Honda CG125 , 15 CBR300R (Chocolate Crank, Deaded), 16 CB500FA, 19 Honda Forza 300, 70 Suzuki SV650

[Teflon-Mike]

[blurredman]