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Discussion Starter #1
I installed some PD Nerf bars on my KLR and I noticed at around 4,000 rpm's that the vibration would cause a loud buzzing noise. I bought some neopreme washers and put them between the mating metal on the two top connections. Buzzing is still there, but not as bad. I think I will try putting a couple of the neopreme washers in instead or look for some thicker rubber washers and see how that works when I have time.

Anyone else try anything that worked?
 

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Mine did the same thing after the KLR fell over and that middle support bar(s) got shifted/bent and was making contact with my voltage regulator. Even though it was just barely touching it, it made a surprising amount of noise. Once I shifted/bent it back, the noise went away.

Might want to take a second look at the area where those overlapping flat bar things pass through around the frame, voltage regulator, fan etc. and see if there is any contact being made there. If there is, not only would it create an annoying buzz, but could eventually cause damage to whatever it's vibrating against.

I doubt if it's any of the joints on the bars themselves, rather some component of the bars making contact with a component on the bike. Another likely suspect is the clamp thing where those two support bars overlap and are attached to the frame.

Hope you're able to pinpoint the source of your problem. I'd be interested in hearing what was causing it.
 

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Vibrations and other noises drive me nuts (I know, short drive!). My HTPD's came with some little rubber washers that go between the two upper mounts on each side. Sort of thought they were a cheesy way to mount things. Never had any noise issues from them though. I have since removed the front rubber washers and sandwiched two home made "L" brackets for mounting Denali LED's. Still no vibration. Eric is probably correct about another component coming in contact with the HT parts. HT could have done a better job around the voltage regulator... Too close for comfort in my book.
 

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My HTPD's came with some little rubber washers that go between the two upper mounts on each side. Sort of thought they were a cheesy way to mount things.
Maybe they were offered as a way to hide the inevitable gap between those mating surfaces. I've tried shifting mine all different ways and still wind up with a large, uneven gap between them. I finally just gave up, but did the same thing and sandwiched a bracket between the two pieces on the right side for my backup headlight.
 

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Discussion Starter #5
I did go on an empty road, ran it slow up to the 4,000 rpm vibration point and found the main problem to be the front left joint. I am going to take another look at it more thouroughly tomorrow. I was too busy going on a rode trip with my daughter today.
 

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I did go on an empty road, ran it slow up to the 4,000 rpm vibration point and found the main problem to be the front left joint. I am going to take another look at it more thouroughly tomorrow. I was too busy going on a rode trip with my daughter today.
Ha! Can't count how many times I've gone down the road systematically eliminating one thing after another trying to find the rattle!

Safe journey with the daughter today.
 
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