Oh boy, rattling sound detected...

[CT_Ron]

Here we go, it's problem time: I have a very weird rattling sound at exactly 2500 rpm while driving. I do NOT have it when I stop and rev the bike to 2500 rpm in neutral or gears while on the center stand. It's gone pretty fast as soon as I pass the 2500 rpm.

I changed the air filter about three weeks ago. I dropped one of the 6 air box screws on top of the engine and I was like 'meh...'. Eventually the heavy rattling while turning to the right got to better of me and I dismantled the bike again and fished out the screw. Put everything back together, problem solved.

Today out of nowhere it makes a weird, cheap plastic like rattle somewhere up front. Somewhere near the dash area, but it could also be near the front part of the engine. I pulled over and revved the bike in neutral to 2500 rpm. Nothing. I revved it to 2500 while on the center stand, in first and second gear. Nothing, just loud exhaust noise. I start driving and the rattling is back again. In every gear, at 2500 rpm, while accelerating. I don't notice this when decelerating and hitting the 2500 rpm mark.

Bear in mind, I hear this crackling/rattling while wearing a silent Shoei Neotec II helmet with Alpine ear plugs

Now while typing this post, I remember that the only thing I changed to the bike is that I removed and threw away the visible allen head screw holding down the lower part of the left side fairing. It was stuck so badly I almost had to cut away the plastic around it so I removed the bolt once the side panel finally got loose after a lot fiddling around. But I don't think this is the problem. I only hear it while actually riding.

I don't think (hope...) it's something mechanical, since it suddenly started after I dismantled the crash bars, side fairings, flipped up the gas tank and removed only the airbox. I did not touch any engine parts.

I'll try and record it tommorow.

[__Ray__]

A long shot but happened to me, check the headlight dust covers. Once i thought de knobby tyres screwed me up in a tight corner and at home i noticed i didn't have a full turn to the right. First i thought of a cable or something bt it seemed a dust cover.
Didn't noticed a rattle but i had some metal on the headphones. it is plastic though so it could easily make a cheap plastic rattle sound.

[CT_Ron]

I too listen to metal

Dust covers are sealed nice and tight. I thought I was able to do a ride today, but apparently I already made plans (thank god for the wifes in our lives). I will try and check it out tommorow, or maybe tonight. Gonna have put my Sherlock hat on for this...

[CT_Ron]

Originally Posted by __Ray__

A long shot but happened to me, check the headlight dust covers. Once i thought de knobby tyres screwed me up in a tight corner and at home i noticed i didn't have a full turn to the right. First i thought of a cable or something bt it seemed a dust cover.
Didn't noticed a rattle but i had some metal on the headphones. it is plastic though so it could easily make a cheap plastic rattle sound.

Lucky shot. Even before I took a ride, I tapped the side fairing with my legs and I could hear the rattle on the right side, with the engine off lol. If I clamped my legs against the fuel tank while riding, it disappeared. So for the fourth and hopefully last time this year, I took apart the side fairing, tank and airbox, and reassembled it, making sure all the plastic rivets, plugs, screws and bolts were tightened correctly. I tapped the tank and revved it to 2K and 2.5K rpm, and I heard nothing. 

[__Ray__]