ok heres an update!
I wanted to check the head bearings to make sure they were well greased. so I removed the fuel tank, lowwer fairings, upper fairing and headlight, front fender, front brakes(from rotor, i didnt open the sys.) front wheel, front forks and finally the head asmbly. When i first got it apart i didnt see anything "bad" there was a small amount of grease on the head bearings and in the neck... but i mean a small amount. I cleaned out all the old stuff from the neck and the bearings and repacked them with red tacky grease. greased up the neck area real good, then i saw the upper grease seal was boogiered up. I know its a order item so i just cleaned it and got it in the best working shape I could. Reinstalled the head asmbly and tightened up the lowwer jam nut thing. Then I reinstalled the front forks and set the height on them, tqed that stuff and put on the fender, inspected the front wheel bearings and wiped out some old dirty grease and replaced with new, installed wheel& tqed, installed brakes& tqed. Ok now with the front end kinda together i started tighting down more on the head asmbly jam nut. i got her good and tight and never really felt the head tighten or drag any more. ran the 2nd jam nut down and then finished up tqing and replacing the front end. got her on the ground and went for a eazy strole around the block, brakes felt odd the first 5 or 6 times i used them but then cleaned up. ok feeling safe i went out and got up to speed and did the normal front braking ...... no click, repeat, no click, 3 more times and still no click COOL. So i get back towards my house and deside to really hammer down on the brakes. I really got the front hard(no brakies) and it had a very light click.
So I figure it was play in the head bearings ect. and when i get the new upper grease seal ill really tighten the hell outa it to make sure its not gonna click.
'05 ZZR600 lowered, 2 brothers carbon m5, stage 1 dynojet, k&n,timing advancer, kca removed, zero degree db, turn 6 led fronts, rear intigrated taillights/blinkers led by L.P. trimed up the stock rear fender, Denso Iridium's, xenon lights, Batt. tender port, tank mount for video camera or gps, polished alum. "ZZR" chain guard, GPS hardwired cradle, Aux power outlet, sr-i500 alarm, frame sliders, custom led flasher control, real carbon tank guard, solo rear cowl, remote mounted garage door opener, r6 rear fender(shock guard), rear wave rotor, +1 stealth sprox,NRC left cover, gathering stuff to install zx10r wheels and front wave rotors.