1980 KZ440 Engine Noise (video)

I was doing some work on the bike (cleaned exhaust pipes, changed sprockets and chain, lubed rear axle bolt) and when I put everything back together I noticed a ticking noise coming from the engine. I can barely hear the noise at idle but revving up the bike will make it show up. Riding is the same way - when the revs drop down enough the noise volume lowers as well.

1980 KZ440 Engine Noise

I'll be checking tomorrow if tightening the nuts in the exhaust helps as I read an exhaust leak could make a similar noise. When the engine is warm I still have the noise though. Looking for other ideas on what to check.

That sounds like the tensioner. When did you service the timing chain tensioner last?

I took it out earlier this week but it seemed fine. Spring was above the service limit. I will have to take a closer look. Anything in particular I should check? The bike has the automatic tensioner.

esquare12 wrote: I took it out earlier this week but it seemed fine. Spring was above the service limit. I will have to take a closer look. Anything in particular I should check? The bike has the automatic tensioner.

That's why you're hearing it now. It's probably sticking. Go start the bike and whack it with the handle end of a screwdriver and see if it shuts up. If not you'll have to service it and replace the spring. The Vulcan guys have success with unscrewing it all the way out and letting it go. It'll spring back in quickly and set in the right spot. Automatic tensioners are the devil. Go to a manual and this won't happen again. These guys make the best ones on the planet  www.tocmanufacturing.com/ManualCamChainTensioner.htm They specialize in Vulcan tensioners, but they'd likely make you one if asked. it is supposed to fit the KZ1000, so maybe.........

Do you (or anyone else) know if "exceeds the service limit" for the tensioner spring means it has less than the free length service limit? Limit is 39mm, mine has 42mm. Being a compression spring I think the longer it is the higher the force it makes to tension the cam chain.

Edit: I cleaned the tensioner and used a fine grit piece of wet sand paper with oil to rub the shaft on the drill. Felt smooth going in/out; there was no drag. I heard it release after I backed out the locking screw a few turns. Ran the engine for a bit but the noise is still there...

I read that if the oil pan is removed I should be able to see the bottom end. I'm in process of doing that (oil/filter is out) to take a look.

Was also going to take out the valve cover to see if anything looks funky. Probably doing this first. I think I can hear the noise near the valve cover. Screwdriver trick makes it sound louder near the valve cover as well. I had adjusted the valves a while back before this noise came up. After the noise came up I re-checked the clearance and was still were I had left them (0.20mm, spec is 0.17-0.22mm).

I know this topic is now 2 years old, but I am very curious if you ever solved the problem.
My bike (a Z440) makes exactly the same sound since a couple of weeks now!