I believe the valve clearances would make it difficult to start rather than make that noise.
My last fzs600 was at 120,000 miles and never had the valve clearances done!
With the cam chain tensioner being on a pressure ratchet it will automatically extend when you take it out so cannot be relied upon as an indication of how far extended it is in the engine.
When replacing the tensioner did you remove the valve cover and check that the cam chain was tensioned and all the timing marks were in alignment?