My front sprocket cover touches the chain guard where they overlap. This causes a god-awful rattle at certain speeds/rpms. I've tried inserting a slab of rubber between the two and that fixes the rattle but it eventually worked its way out. I then glued it in there and it lasted a few more miles this time but still came out eventually. Now I'm thinking about drilling a small hole in the belt guard and mounting a rubber bumper in there with a bolt and a nut.

Anyone else have rattle issues in that area? What did you do to fix it?

my 06 does the rattle there  also..
suzuki has a pad that "sticks" to the cover to isolate it from touching the guard..
been through 3 of them so far,after saturdays rain ride sounds like i need to dig the last one outa my desk drawer..
they dont stick!!
chrome on the gaurd is raw at the rub point..

Before drilling holes in my *belt* guard, I tried one more thing. I cleaned the guard with degreaser and stuck on some of those felt pads you can get at hardware and craft stores. I use the little ones and placed several of them in the area that's normally covered by the sprocket cover. The idea being that maybe the rubber pads weren't allowing the parts to move independent of each other and that was causing the rubber to work its way out and onto the ground.

I took it out for a 20 mile ride and the felt pads are still in there. They didn't move at all! Problem solved!