New Lyrik Fork has a rattle.....possible cause?

[kombos]

I just bought a 2020 Levo Comp last week. I'd ridden a stock rental the day before so I knew what the fork felt like.
I'm about 145 lbs. (66kg) so decided to go ahead and remove the two fork tokens based on rsilvers (thanks) postings.

I did not ride the bike before removing the tokens so don't know what the fork sounded like before I worked on it.
I removed the air cap, unscrewed the two stock tokens and reassembled. I then pressurized to about 75 psi.

When I ride the bike I hear a rattle in the fork when I'm riding over choppy rocks. It sounds like something tapping
on the fork tube inside. I cannot reproduce by simply bouncing the fork up and down, either on or off the bike.
It seems to me that the rattle is not caused by something moving up and down, but rather forward/backwards.
Fork works fine otherwise.

Any clue as to what this could be? Seemed pretty simple to pull the tokens and not sure how I could have
messed something up. Looking to see if anyone might have a clue before I revert to putting the tokens back in.

Thanks in advance.

 

[ebikerider]

If you have the torque caps fitted to the hubs it's likely to be them. Removing the tokens is probably just a coincidence. Best way to stop those torque caps rattling is to pull them off...they are just an ornament lol

 

[Tricati01]

Also check the pre-load on your headset

 

[Mikerb]

Assuming both bolts on the bottom of the fork lowers are tight I cannot think of anything else in the fork that would rattle. More likely to be the headset. With the torque caps I push a bit of grease behind them and that stops them making any noise.

 

[kombos]

Thanks for the inputs. Some good calls....but.
I checked the headset and it was indeed loose (don't know if the factory set this or the LBS when they assemble). Adjusted it to remove the play. Thought that was it, but next ride still had much of the rattle up front.

Had to look up what the torque caps are. They indeed do have a little side-to-side play in the direction of the axle. I thought that maybe I'd add some o-rings, but there are already some inside the torque caps. Don't think the little movement side-to-side can account for the rattle I'm hearing. Seems more substantial....I think.

Bolts on the bottom of the fork? One checked out tight. The other leg has the little rebound adjustment knob.

 

[CjP]

Have you checked the brake calliper?

 

[kombos]

Have you checked the brake calliper?

Thanks....checked all four bolts. All tight.

 

[Mikerb]

OK, one other thing to try. The front caliper cable crosses the inside of the left fork lower. I found that rattled against the lower on my bike. I cured it by supergluing a small square of neoprene onto the cable at the point it cross the lower.

 

[kombos]

OK, one other thing to try. The front caliper cable crosses the inside of the left fork lower. I found that rattled against the lower on my bike. I cured it by supergluing a small square of neoprene onto the cable at the point it cross the lower.

Will try that and report back....thanks.

 

[JMD]

Check the cables inside the top tube that run either side of the TCU.
Mine rattled when fork went up & down.
I first thought it was my fork.

 

[kombos]

Check the cables inside the top tube that run either side of the TCU.
Mine rattled when fork went up & down.
I first thought it was my fork.

Thanks...what did you do to solve?

 

[Mikerb]

You can remove the TCU and check them or simply pull or push them a little where they enter the frame whilst checking they stay still where they are visible by the shock. The TCU also has a fair amount of spare cable so that it can be removed from the frame for firmware updates etc without disconnecting it. The wiring connectors are quite hard and will rattle if against the side of the frame. Tidy up the excess cable keeping the connectors on the inside of the bundle you make.

 

[kombos]

OK, one other thing to try. The front caliper cable crosses the inside of the left fork lower. I found that rattled against the lower on my bike. I cured it by supergluing a small square of neoprene onto the cable at the point it cross the lower.

That was it! I put a little strip of foam between the fork and cable for isolation....silence! Thanks much for the suggestion.
(I thought it sounded like something hitting the fork tube, but wouldn't have thought the cable slap to be that loud)

Check the cables inside the top tube that run either side of the TCU.
Mine rattled when fork went up & down.
I first thought it was my fork.

Appreciate the input. Wasn't my issue, but may help someone else reading this thread.

 

[Mikerb]

Great....nice when you solve a rattle. This is how I did it.

 

[Levo-Lon]

If you have the torque caps fitted to the hubs it's likely to be them. Removing the tokens is probably just a coincidence. Best way to stop those torque caps rattling is to pull them off...they are just an ornament lol

I used waterproof white grease on mine on my specialised Epic xc bike to silence them, drove me mad looking for the rattle on my first long ride.

I think they are for certain forks..but easy to pop off and hit with big hammer until your tired ?