Good info from all I happen to have a new rubber mallet I I might take some swings today to try and pin point the root cause. As far as the gas cap that was i think the first thing I grabbed while riding to see if that was the problem and sound was still there.

 

So I think I figured it out and now I’m a little stumped on how to fix this issue. Today was around 80 deg and was out riding. Decided to pull into a forest preserve and let it cost in 1st while I look down. So I believe I found the problem seems as the motor is jumping the rear pipe going down to the muffler is about 1/8 from the pully cover and as the motor is jumping its making contact just a touch but enough to make a chatter sound.
What can I possibly do without removing the pully cover.
i plan I just removing it to be a 100% that’s the problem
and if it is then what steps can I take to correct this with out loosing my cover. I know I can probably replace with after market smaller one but would like to keep stock.

 

Could be that your rubber engine mounts are shot making the engine jump around a little more.

 

is that normal wear and tear or unusual? If so is the rubber a hard Chang?

 

Don't know. Never changed them. I would think them wearing out would be normal wear and tear.

 

Replacing the rubber motor mounts can be a bit of a struggle, but not too bad. i did them on my bike when i hardtailed it. I had pulled the motor completely out of the frame, so maybe that actually made it a little easier?

 

Yea sounds like a job. How can I check to see if they are even bad? Bike is only 6 years old and 2500 on the clock

 

If you look from the front of the bike, under the frame, you should see the front ones. i believe that if they are sagging, they need to be replaced. How many miles on the bike?

 

Try putting a washer or spacer at the mounting points to gain some clearance.

 

2500 miles