New rattle after removing head

[FJ_Hooligan]

Check for exhaust leak at night with the lights off.  You should be able to see flashes at the header pipe/head joint.

[Paul.1478]

Check for exhaust leak at night with the lights off.  You should be able to see flashes at the header pipe/head joint.

Good idea and I will but I am 99.43% sure there is no exhaust leak. just that rattle at 2000 RPM.
There was when I first put it back together but that was because I had 2-3 pipes mixed up.
They may be misaligned causing rattling. I hope to have time tonight to take them off one at a time and be sure they are seated properly. 
OR it can be coming from some innocent place but I cant find it.
All the parts in the head look good to me.

[FJ_Hooligan]

Are you sure it's not something in the fairing resonating at that RPM?

[racerrad8]

The front guide should have a nice curved arc.

See the two photos here: http://rpmracingca.com/proddetail.asp?prod=36Y-12251-00

Randy  - RPM

[Paul.1478]

Are you sure it's not something in the fairing resonating at that RPM?

No I am not sure at all. I wanted to eliminate the thought of it coming from the motor.
I did find one of the metal break line (maybe for abs?) right above the valve cover that was loose in the metal holder. The rubber mount came out. When I get back I'm going to remove exhaust and put it back. If that does not do it maybe I'll pull the fairing off. 

[Paul.1478]

The front guide should have a nice curved arc.

See the two photos here: http://rpmracingca.com/proddetail.asp?prod=36Y-12251-00

Randy  - RPM

Thanks Randy.
I bent it until it fit back into the slot in the head.
I was going to come by Monday for a quick
Visit and If you have them in stock I may just get one and replace it.

[Paul.1478]

This is still driving me nuts. I have removed the valve cover and re-re-checked everything.
removed the exhaust and put them back on, just removed the fairing yesterday and still makes the exact same noise. It is very hard to tell where it is coming from depending on were you stand. Sometimes sounds like coming from the valve cover sometime the fairing some times the exhaust.

Could I remove the exhaust and start it or will this do something bad to the valves (cold air?). I figure if I remove it from the equation like the fairing it will limit the places it can be. 

Thanks 

[Old Rider]

Okay i think i see whats wrong it is the front cam chain slider .It is supposed to stick a little above the gasketsurface mayby 5 millimeter your is to far down into the slot.

[Paul.1478]

do you think that could make it make this notice? I don't know.
https://m.youtube.com/watch?v=OJlk3RX63cA

[Old Rider]

do you think that could make it make this notice? I don't know.
https://m.youtube.com/watch?v=OJlk3RX63cA

Im not sure but mayby the chain gets wrong tension and slap up in the  valvecover .The sound also sound like vibration have you checked the clutch line or something lose ?.
You can start engine without the headers.When i now locked at the pictures again im not 100% sure that the slider is to far down but it looks like it is.If you have a pick from side its easier to see.
On mine the front slider sticks  4-5 mm above valvecover gasket surface

[balky1]

Find a stetoscope and try to check with it.

[FJ_Hooligan]

Start it up without the header pipes on and I can guarantee that you will not hear a rattle.

[Paul.1478]

You sir are 100 percent correct.
I think I know what it is now after speaking to Robert. I fixed this.

Problem is now the cam cap threads I had "fixed" in the head by a local machine shop are F-ED.
I have a new helicoil but it also is not working. It will not tighten down.
Check the for sell tomorrow. I good deal in a 93 is coming....

[Troyskie]

"Check the for sell tomorrow. I good deal in a 93 is coming...."

Yep, know the feeling.

You've done great work so far. You're close to that 'aaaaah' moment.... and at the end it will be a bike you can trust.

[Paul.1478]

cam camps fixed by a good friend. Noise gone. it was the cam chain guide on the exhaust side. it was not located correctly.
now the bike has a huge leak and not from the valve cover. not sure how that is possible because it was not leaking before and I only removed the valve cover. 
Oil cleaned and corn powder going on tonight or tomorrow to try and ID the location of the leak.
This bike is trying my patience and I am about out of patience.