New noise

[Mattman]

It sounds like you have a tight spot in the chain, check the freeplay at different spots if thats it you need to replace the chain and sprockets as a set.

Chain is still too tight.  Loosen it some more and listen again.

Okay, I went back and untightened the chain some more.
The noise diminished even more, now it's just a faint "knocking" sound, which can be heard if you put your ear close to the front sprocket.
Or like in this video below, push your camera against the left side of the motor.
It can just be heard above the metallic sound of the rear brakes dragging on the disc.

Your countershaft sprocket teeth are a bit "hooked". 
How are the teeth on the rear sprocket?

I tried to get a good shot of the rear sprocket teeth on the video above.

How does it sound when you rotate the wheel in a forward direction?

Same sound. The noise is irregular, so that if I hear it, then rotate the wheel back and try rotating it forward again, the noise is gone and comes back after rotating the wheel another 1/4.
I can actually feel this when moving the wheel, like a small roughness when rotating the wheel.

Okay, so I'm now positive that I had my chain set waaaay too tight. It was not completely tense, but needed a bit of force to push it up or down.
I had it like that for about 500 miles of not-so-hard riding, before this noise showed up.

I have a trip planned for this weekend, to ride my FJ away to where I normally store it for the winter, before the weather over here gets too cold to ride.
That's a 400 mile ride.
In the winter, my plan was to change the rear wheel to the GSXR one I have hidden away in the barn, together with new sprockets and chain.

Now I'm wondering if this trip is such a good idea. Would my chain be in a bad condition after the beating it got through the too-tense riding? Is there any chance that it will break?
I do not know what kind of chain it is, it was installed together with new sprockets by the PO not too long before I bought the bike, about 2000 miles ago. 1500 miles of that was with the chain adjusted loosely, rather than tight, with no hard riding.

Any advice?

Thanks,
Nat

[FJ_Hooligan]

Take the chain off the sprockets and rotate the countershaft sprocket by hand to see if the noise is still there.

[WhiteBeard]

Thanks for the guidance.

The FJ is going on a trailer, to be safely transported to it's winter shed on the other side of the country.

An EK ZZZ 530 120 link gold chain is on its way. Sprockets and wheel bearings are coming next. And an EBC disc for the GSXR wheel.

Better be safe than sorry.

I will keep you updated on my findings.

/Nat

[WhiteBeard]

The bike has been transported to the Northern Regions, to stay there for the winter.

Checking the bearings next.

I've bought a new set of wheel bearings for the GSXR wheel, new chain, steel sprockets.
A new swing arm which will be polished and installed with new bushings and seals.

Well, at least I have plans...

[turbocamino]

I havent seen it mentioned....several of us,including myself have found the countershaft sprocket finger tight...there is (should be) a safety washer but mine was very loose...it could rattle i bet.

[fj johnnie]

 I had a similar noise from mine and it was a worn front sprocket. As I have a spare motor I swapped it for a newer used one and the noise disappeared. A new sprocket and lock washer is not expensive.