I have been struggling with clunking noise from the bar while sprintong/climbing hard or just rocking left and right. Did everyone I could think of. Played with torque on all related hardware, increased clearance with headset cover/ fork top. Issue seems to be coming from the bar itself. I inspected it many times, without any cracks findings.
I am writing here before going to Chris for warranty request since I have the bike for more than a year, but has been struggling with that issue since day 1.
Anyone faced that issue?
1. With carbon frames sometimes is hard to determine where the noise is coming from. I had a similar issue. I was sure the noise was from handlebar, headtube and it took me sometime to figure out that is was from the saddle!!.
2. Be sure that you can reproduce the noise standing up or moving the handlebar when you are not sitting
3. We do not know if you have an integrated handlebar or a stem/handle bar.
4. If you have a stem/handlebar, sometimes the noise comes from there. The easy way is lose the front plate, wrap the handlebar with teflon tape (the one use in plumbing) and thigh it.
5. If noise still is there, when you rock the handlebar with the bike still, press the front brake, place your hand around the fork headtube and rock the bar, If movement then you have to tight the headset (or replace it)
6. How many headtubing spacers did you have? are they setup correctly (pins and holes aligned?). The expander bolt that comes with the frame is short one, if you have extra spacers you can get longer expander bolt from Alibaba. You have to measure the distance from the hole inside the headtube that allows the front brake hydraulic to go inside of the fork)
7. If you can reproduce the noise with the bike still, it means rattling the internal hydrauiic cables is not the issue.
8. Finally the last alternative like other users suggested is to take everything apart which ain't easy. If you get to this point, get some hydraulic cables sleeves and sliding them inside of the frame so you will not get rattling. You will have to change the hydraulic tubing etc etc.
9. If all is OK and you get the noise when sprinting out of the saddle the press-fit BB is the most likely cause.
Good Luck. Chris is great but is very hard to diagnosed this type of problems over an e-mail ;-)
Ciao and Good Luck