Has anyone experienced a knocking noise associated with the floating rotor and caliper on the front brake? If so, how can you minimize or eliminate it?

Describe the "knocking noise" a little better.  When does it happen?  Is it a single "knock" or a repetitive thing?  How old is your bike and braking system?

You're not talking about the low-frequency "buzz"  that you hear at low-ish speeds when you apply the brake, are you?  I just installed a new rotor and pads, and I'll be hearing that sound for a good while, until the pads get well bedded-in.  I kinda like it actually, but I can't hear it very well until I slow down enough to overcome the wind noise.

Possible the caliper mounting bolts are loose and allow the caliper to rock against the fork legs when the brakes are applied.

It's a repetitive knocking noise, most noticible at around 10 mph. Frequency decreases as bike slows. I am familiar with the buzzing sound caused by the drilled rotor, it's not that. Bike is a 2003. Noise has been there since day one. Dealer says it's from the floating rotor and caliper and not to worry. I'm not comfortable with it.

Caliper bolts on fork leg are tight. I checked that.

Quote from: ddaltonbDealer says it's from the floating rotor and caliper and not to worry.

Quote from: ddaltonbI'm not comfortable with it.

Nor would I be!  They'd better either come up with hard & fast evidence about why it's OK ... or fix/replace it!

Is it maybe a clicking noise, such as ball berings in a race falling on top of each other?

The only other thing I can think of is maybe the speedometer drive.

It's a repetitive noise related to wheel speed and unless there is something mis-aligned with the caliper and disk, the caliper and disk should not make a nocking noise. Now, that I typed that, can you prop up the bike so that you can spin the front wheel and look at the disk and caliper from the front, and slowly rotate the wheel, and look to see if anything is contacting the caliper? I'm thinking the hollow circular connectors that the disk 'floats' on, maybe contacting the fork leg?

Is the spacer in place between the rim and right fork leg (picture Kerry?)?

Here is the front axle with the spacer in place -- and the bolt, nut and cotter pin that secure it:



This photo shows the actual position of the spacer:


(Golly - everything is so DIRTY looking!   )

Quote from: scratchI'm thinking the hollow circular connectors that the disk 'floats' on, maybe contacting the fork leg?

I think scratch may be on to something here.  Only I think the connectors may be contacting the caliper mounting bracket?  See what you think: