I have a very very annoying high-pitched rattle/vibration/whistle coming from the front of my 07 SERK. I have had it to the dealer, they acknowledge the sound but cannot find what it is. They have removed the heatshields (noise still there), rocker covers(everything tight), etc. and the sound does not go away. Has anyone else had this issue and found a solution? It starts after warm up, seems to be the most noticable around 2500 rpm. I can lesson the sound by applying pressure (stepping on the heat shield by the floorboard). The dealer gave up - said that HD will not reimburse them for looking for a problem, only for fixing a problem. It is bad enough that others have noticed and commented on it while riding.
First things first. Whether Harley will reimburse them or not they are still obligated to service the problem. They made the profit on the sale. They're obligated. It's obviously an issue presented within the warranty period. Do not let them get away with telling "it's not our job" because it very specifically is. You let them get away with this nonsense you'll be railroaded every time from now on that any question or issue comes up as they'll assume they've got an easy mark.
Having said that; it sounds as if you believe it's an engine noise. You also said it presents in the 2500 RPM range. Does that mean you hear the noise even when the bike is sitting still? Or do you have to be moving down the road?
If you hear it sitting still in that RPM range then you've isolated it down to moving parts (engine and primary and things attached). If that's the case then definitely make the dealer look farther. Otherwise you're begging to be calling for a trailer along way from home sometime.
If it only make the noise while moving down the road, however, look for things like a contact between pipe and floorboard bracket, loose air dam under the tree or, unfortunately, anything else that wind might be flying by.
But for god's sake don't let the dealer get by with telling you "yeah, you've got a problem, I can hear it, it's not my problem."