Spent the better part of an afternoon trying to get the primary adjuster slid back up into place. The reason for the adjustment was to see what is making the noise inside the chaincase. Sounds like someone's inside hitting it with a hammer! Doesn't matter if the clutch is engaged, it still knocks. My guess is a bearing, but what symptoms aside from knocking will lead me to the culprit? Fluids (primary, tranny, engine) are all up, and no visible leaking. Would a motor mount knock at idle? Only hear the noise on primary side, but I do know noises are hard to pinpoint on running motors. If it's a bearing coming from the primary or clutch, what damage can be been done by riding it. You know, if I ride till it stops, then I'll have known what caused it right?
Thank you to all help.

 

My first guess is your compensator nut worked it's self loose.

 

Yep, sounds like you are describing something in the compensator, bad spring, nut loose, etc. But as with all cyber diagnoses, it could be something else entirely.
John

 

A loose compensator nut hitting the primary cover will make that sound.

 

Which might help explain the perpetual drive belt adjustment, right? And the major vibration in low rpm downshifting? My next question is; anything to look for before I tear off the chaincase cover? Anything after? Why would the nut come loose is another question? I'm saying you guys are right, and I'm asking what else needs to be done AFTER the cover comes off.

 

Why would the nut come loose?
First probability is lack of red lock tight on the threads.

I'm asking what else needs to be done AFTER the cover comes off?
A very close inspection of everything. See if anything is cracked or in any way damaged.

 

"Why would the nut come loose?"

Short answer: because it can. Such is the nature of threaded fastenings subjected to vibration.

 

Red Loctite and 165 ft/lbs will keep it sweet :-)

 

Of course, as I found out, it can also be the chain dropped so low that it was banging the crap out of various ribs inside the case! Then, after I dropped the gasket on the garage floor, I wiped it off soooo well I tore it in half!
Life's been good to me so far!
Resistance is futile-you will be assimilated(heavy on the first three letters).

 

If your chain is that loose then it might be time for a new one.

As for the gasket get the new ones made of foam covered metal.
They are hard to mess up and you can reuse them a few times.