05 yz250 fork noise?

[gearhead119]

I am noticing a slight clicking sound coming from the forks on my buddies yz250 '05. Thought it might have been the floating rotor or loose head bearings(they are fine) but after removing the forks you can "feel" a "click" about 4 inches into the travel. both do this. and we have had both apart and everything seems to check out ok.. They had been revalved by an aftermarket company but everything seems to work well..just annoying! when installed on the bike they become even more noticable. has anyone else ran into this problem?

 

[_JOE_]

I know a guy who DIY'ed a set of seals on his 05 yzf250 and had the same knocking sound. I'm interested to see if someone has a diagnosis.

 

[Danger]

I know of two brothers with '06 YZ250's who both report the same clicking. Yamaha even changed the inner chambers on one of the bikes because of the noise, a suspension tech has worked on them but still they click. I have not investigated the cause myself but I'm interested in the cause.