after warming up, my 09 foreman makes a rattling noise at a certain rpm in each gear. at 5mph in 1st gear, at 9 mph in 2nd, at 13mph in 3rd, and 18 in 4th. 1 mph faster or slower and its gone. but it's driving me crazy. will also do it in neutral as you increase the throttle and pass thru that specific rpm. honda mechanic thought it was in the frame - retorqued motor mount, removed and replaced fenders, heatshield, etc. i think its internal as it only does it after warming up. only 180 miles and done it since day 1. help!

 

Welcome to the forum.

Without being able to hear it, it is kind of hard to guess.

Has the break in service been done (valve adjustment)?

 

+1..............................

 

yes. first service was completed at 70 miles. took it in early cause the noise was aggravating me. not valves. took atv to another honda dealer yesterday and will see what a different mechanic can do. he said it could be muffler internals commonly but he hasn't actually checked it yet. thanks.

 

Can you get it to make the noise when not in gear?

If so, you might go around and grab various parts, or if they are hot press on them with your boot or a block of wood.

You may want to remove the tank cover, and maybe also the tank to look for anything loose.

A buddy of mine had a harley that you would swear was spinning a bearing. Turned out to be a muffler hanger that you never would have guessed could make a squak like that.