Ok here is the deal...Today is the last day of my extended warrenty...My cam chain tensioner is knocking like a bastard...startup and low rpm's up till about 3800 then it quite's down untill 5000 and quite's down again at about 6000 just like pretty much everyone else's...Like I said today is the last day of my warrenty and I have not had a claim on it yet...So I go into the dealership to see if maybe they can hook me up with a new one under warrenty! Well the service manager tells me that he got me a claim but i will have to bring it in next week for him to look at, If it is warrentyable then no charge to me...but if it's not then I have to pay for the tear down of my bike and its still not fixed...Just looking for advice or some words of wisdom...

 

If you are sure it's the tensioner and not the chain I would just buy another tensioner. Changing it is not hard at all and requires no teardown whatsoever.

 

So is the service manager telling you that the noise is not normal and that it needs fixing?
That there is something wrong and the only decision is whether it is covered by warranty or not?
If I had a noise in my engine that I thought was a "problem", and not just an acceptable amount of cam chain rattle, and an "expert" also thought that the noise was not right, I would have it fixed.
Me, I would do it myself.
If I was not confident to take it on, I would pay somebody to do it for me, regardless of who pays.
To ignore it asking for trouble.

 

It's gotta be done so just hope they warrentee it.

 

It seems more and more people have this problem. 90% postive that it is the cam chain. Mine had that same issue. Replaced the tensioner as suggested by the Kawi mech, no change. Tore everything out and replaced the cam chain and guides. Problem solved. It has been quite since then for the past 1,500 miles.