There's been lotsa speculation on the causes of F800GS front end clacking. I think I may have found one cause, and I came up with a solution. I was installing new Ohlins front springs so I had the upper tube caps off, and the old springs removed. I noticed that there's a black plastic inner spring guide, on the upper damper rod, at the top of the tube. It's got 4 ribs on it, and it's about 8" long. Refer to part #3 in the diagram below (these drawings are SIMILAR to the actual parts in my forks, but not identical). Photo being updated 3-29-10 The spring guide has some free-play on the damper rod. It can move up and down a bit as it guides the spring and keeps it concentric on the rod. The lower position is limited by internal stops, but the upper position is determined by a 13mm jamb-nut that keeps the upper cap affixed to the end of the damper unit. The upper cap is threaded down onto the end of the damper unit, and the jamb-nut keeps the cap from coming loose off the end of the damper unit. It's difficult to loosen that jamb-nut because you have to grip the damper unit at a point below the spring guide so it doesn't turn when you torque the nut. You'll need a long pair of needle nose pliers that can fit between the coils of spring. Or, you can turn the jamb-nut one way as you turn the upper cap the other way, and they'll break free of each other. My curiosity was stirred by the free-play of the black spring guide, so I reassembled the guide, the jamb-nut, and the upper cap, without the spring itself, so I could see how things fit. I worked the spring guide back and forth on the damper rod, and lo-and-behold I heard a familiar sound! The spring guide made a clacking noise at the top of it's travel, when it hit the jamb-nut. Maybe I was onto something here. Here's what the spring guide, damper rod, jamb-nut, and upper tube cap look like, when the spring guide is in the lower position: And here it is with the spring guide in the highest position: When the free-play is measured, it's about 1/4": I have a bunch of prototyping bushings and spacers around the shop, so I picked our a couple 1/4" x 1" diameter thick buna rubber bushings with a 5/16" center hole, just the right size to fit on the upper threaded end of the damper rod. The bushings were smaller in diameter than the 4 fins of the spring guide, so they won't hit the spring. I threaded the jamb-nut on the end of the damper rod, and slightly compressed the bushings, then threaded the caps in place. I then tightened the jamb nuts up against the bottom side of the caps and checked for clearance between the bushings and the jamb-nuts. Perfect. I took it all apart, installed the springs into the tubes, fit the rubber bushings and jamb nuts, and top cap in place, and tightened them against each other. No more free-play of the spring guide, it was snug and comfy. Here's what it looked like: The rubber bushing can be seen below the jamb-nut and the spring. There's a bit of grease on the bushing, which I found necessary to get my wrench onto the jamb-nut. The rubber bushing cuts down on your available working space, so my usual 13mm wrenches wouldn't fit. I used a grinder to thin out the end of an old 13mm wrench, until it was about 3/32" thick and could slip into the gap between the bushing and the plastic cap, and onto the 13mm nut. I replaced the fork caps and tightened the pinch bolts. Now for the test ride. Before the new Ohlins springs and my rubber bushing mods, the front end would clack like a barnyard goose everytime I hit a sharp bump. But now the clacking sound is gone. Silencio. Shhhhh. A hush falls over the crowd... could this be the solution we've been seeking? Well, it worked for me. YMMV. Update: I had so many requests for these bushings, that I put them on the website. Click here: KlackStoppers PS. The new Ohlins front springs work great, as does the new rear shock. Money well spent. I got them from Stig Pettersson at PPS. http://www.bestrestproducts.com/t-links.aspx Update: The Griz has taken the noise investigation to the next level! Scroll down and read his postings, they shed more light on the possible causes (and fixes). We're getting there! .