This may take a while.
I bought a '00 600 Fazer 2 years ago that had been parked for 10 years after the previous owner dropped it on his leg and broke it (his leg). I've slowly been working my way around the bike fixing it. So far I've done the forks, rear shock, s/s exhaust, upgraded the rear brake to a blue spot, refurbed front brakes, new wheel bearings, ultrasonically cleaned and balanced the carbs and changed the carb rubbers. Just done the timing, valve springs and shims. My next job is to refurb the clutch - plates, judder and tension springs, and cable.
I changed the sprockets and chain first and had the usual fazer knocking/rattle in idle - no biggie.
Riding all year round - in the North of Scotland the chain takes a beating (no matter how much care is taken) and a clutch noise/chain rattle slowly appeared, including a knocking sensation through my left foot, getting slowly worse.
I put it down to a tight link(s) - which I had. The chain snapped last week - no damage done except to my number plate. Lucky me.
With no chain fitted I started the engine and there was a horrible rattling noise from around the front sprocket area - best way to describe it is like a bolt in a blender! There was no excessive play in the front sprocket and after changing the chain and sprockets the clutch noise and knocking had disappeared. Happy days.
I've now done just under 950 miles and the knocking through the left peg has reappeared and is starting to increase along with a grinding/graunching feeling. The chain has no tight links and is in tension, engine oil level is at the top end and the wheel bearing is good. The usual 'Fazer noise' on start up is still there but after riding my commute (67 mile one way) when I stop and put it into idle the noise is 10 times worse - the engine sounds like a diesel!
Does anyone have any clues to what this could be?