"Nope, there's nothing wrong here."
:banghead:
So, I got a call from the dealer today. I said, look, if the wrench can't find the problem, I'll come down and show him. I jumped in my truck and was there 20 minutes later.
The mechanic started to explain to me how the Spyder is different, how an off-camber road can cause problems, how 95% of what is on the forums is nonsense, how laser aligning off the rear wheel is wrong, blah blah blah.
His test ride went just A-OK, too.
He put the bike up on blocks and showed me how everything is nice and smooth, and the ball joints are just fine. I couldn't find the clunk, either, and that just embarrassed me.
He took it off of the blocks, and tried to politely show me the door because he already used his allotment of time on the job, but I can be rather thick, so I kept messing with the tire.
BINGO! I was able to duplicate the problem by pushing and pulling hard on the top of the tire when it was on the ground. He felt it, too, and we could both feel it in the joints themselves. I figure at least .010" (0.254mm) of play in the joint.
There isn't any acceptance criteria for the joint; it's either good or bad. I have always allowed zero play in ball joints, and that much play makes it bad in my book. He didn't think it was bad, but hey, let's keep the customer happy even if he is wrong.
The alignment tolerance is +/- 0.5mm, but I don't know where that is measured. If it is measured right at the joint, the play is eating up half of it before you even get started. If it is measured elsewhere, all of the tolerance is long gone, and the alignment is in the weeds.
I put my massively powerful persuasion powers into turbo mode, and he gradually came around and said they would get the warranty company to cover the replacement and their full-on 3 1/2 hour alignment.
Actually, I was just very nice and reasonable, just like any ticked-off Quality Engineer should be! You wanna talk Quality? Let's talk Quality! heh heh heh.
I should hear back today or Monday.