Ive had steering head hammer in my '07 softail standard from the start, was "fixed" by the dealer at 500km and again at the first service. It always reappears after a few thousand Kms and annoys the shit out of me. RT and I retensioned it again before the Darwin trip, but by the time I got there it was hammering like crazy.

HD Darwin fitted a revised head stem washer kit (part No 4574007). It is made of a thicker guage metal and allows greater torque to be applied to the top head stem nut. It is not covered under warrenty and cost me $44 for the kit and a half hour labour to fit. It is a 80% solution I believe. I still get the occasional hammer on large road irregularities.

HD acknowledge there is a flaw in the design and have supposed to have fixed it for '09 models.

Just thought i'd put this up so if you are having the same problem you can get the "FIX".

Couldnt tell ya scotty.....the dealer did it in Darwin and I didnt think to ask.

Interested in seeing what you have done though.

Hi Greg and Scotty, I've had the same problem with my 07 standard, dealer said it was bearing related and adjusted it at first service, it has started to clunk a bit now again after 20000 ks. In the service manual it states that the stem nut torque should be 35-45 ft lbs and the bearings adjusted with the fall-away test etc.

Bt

over the next few days I will get a torque wrench onto my upper nut and see what the dealers at HD Darwin have done it up to. I'll let you know.

Bob, RT and I adjusted the fallaway to perfection before I left, so all was good there. The stock washer locating tab was well bent and twisted though, which to my thinking means that the Townsville dealer had applied additional torque at some stage. The "revised Kit" is a heaver gauge metal which will allow greater torque to be applied without twisting the locating tab.

I will try to get some pics up today.

On the 08 Fatbob they put a heavy flat washer on for exactley the reason stated by Scottie, done away with the thin plate and locating tab. When I adjusted the steering head bearing at 4000k I noticed the heavy washer, and was done up to 80ft lbs from the factory.

had front end clunking on my 06 wideglide swore coming from triple trees after reading lots of info on u.s site many said loose front tank bolt can cause the problem tried mine was not what i would call loose tightened it up some more problem dissappered good to try before pulling things apart best of luck

not the tank bolt, but thanks for the tip.

Here is the picture of the tourtured washer. The revised kit washer is half as thick again. I still havent put a torque wrench on the nut yet.

 that dont look good

Hi Greg

When the thicker washer was put on how did ya go with bending it to lock the nut?  Gonna look at doing the retighten bit as well.

Doesn't look like this part of the bike was all that well engineered.

Bt

BT

The thicker washer was not bent to lock the nut, and i imagine it wiuld be a tough job to bend it as well. I guess they are relying on the additional torque to lock things in, but i will mark the washer and keep an eye on it though.

No it is not the best design/manufacturing around, but such is life.

Greg

I had a similar sounding clunking on my 07 bob at new and when they took the head apart found the bearings dry, a good packing of grease and it was all good.... scary to think hey

I cured my head stem clunk by fitting the fully chromed alloy upside down front end. OK, not the cheapest method but very effective.