yes, the enhanced freeplay while turning at slow speeds (in my case at one point it had become so bad that there was a significant slow speed freeplay even at straight line movement or when just swerving a little to overtake someone) and that hard "thak" sound from the front end (which is probably what you mean by the rattling sound), which in my case was probably not as loud as in yours but loud enough that it was annoying and discomforting, when moved over speed breakers, potholes of even small sizes, even slightly uneven road or when braked suddenly are the symptoms i faced too..
the freeplay is largely due to lack of lube and the ensuing large scale rusting which hampers proper frictionless movement of the bearings over the conesets, thus giving rise to uneven handlebar movement/rotation which sometimes feels like moving too much while also sometimes like not moving smoothly enough.
the cause of the khat sound is probably not directly connected to the transverse and rotational freeplay of the handlebar. i always thought it was mostly due to some vertical space created (along the front fork) between the conesets, or between the conesets and another ring shaped type object against which the conesets are fitted ..so whenever the front fork gets loaded suddenly, which for instance happens when you brake suddenly or when the wheel encounters bumpers or potholes etc, the setup has some free movement up the vertical direction (that is along the length of the fork) and khat sound is from the banging between the 2 objects described above between which a small space has been created...it can be corrected by adjusting/tightening the nut at the handlebar joint just near the coneset.
i am not aware of the metal cracking sound when the bike is standstill and handlebar is moved..it wasn't there in my bike, or maybe it was there but too slight for me to have heard it.
if the rusting is not a lot, then just lube it and see how it works. or if the rusting is only mainly on the ball racer (which is cheap, i think Rs 500-600) you can buy a new ball racer and fit it over the old coneset with lots of lubing..




sorry for late reply

Comment