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check the bolts there are long ones and short ones if you have a long one in a short hole you will have a rattle
check fender and cowl

A friend with an 04 had this exact symptom. One of the 4 front Cowl bolts was missing! The whole cowl was rattling whenever he went over a bump. It sounded worse that what it was. Made him think his front suspension was broken...:agree:

The missing bolt is $5 and went under the cylinder head down almost at the bottom of the cowl near where the engine guards go around the valve cover.
 

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Have you ever removed the cowl? I'm wondering if maybe something isn't aligned correctly. I've never had a rattle in mine and after we put the bolt back in my friends 04, his rides quiet.
 
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