Tapping noise after engine work

[KLR600]

I recently smashed my sump on a kerb and ripped the sump plug out:

https://img.photobucket.com/albums/v331/serenaur/IMG_8515.jpg

(Yes I know, idiot move ) but I stopped the bike before all the oil leaked out and pushed it home. Fast forward a few weeks and I've sourced and fitted a second hand sump from a breaker and all is well apart from now there is a loudish ticking coming from the left hand side of the engine (cam chain side) that wasn't there before I broke the sump.

I've taken out, stripped, cleaned and re-installed my cam chain tensioner but that hasn't changed anything. It wasn't anywhere near full adjustment when I took it out so I think that would suggest the cam chain isn't worn out yet. Flip suggested that as I had to take my downpipes off to change the sumps that maybe I hadn't tightened the header bolts up enough causing a tapping noise but I re-checked them and they were ok.

So that's me out of ideas. Here's the symptoms:

The tapping only really happens under acceleration but you can hear it a bit at constant throttle just not as pronounced. it doesn't happen when decelerating.
It gets louder the harder the acceleration.
It doesn't get any louder or quieter as the engine warms up .
There is zero loss of power/performance from my bike. (although I've only actually tested it on short runs and stuck to 30 and 40 limits).

Any ideas? I'm worried that using the bike while it's making this noise is causing some kind of long term damage but I need to make some long journeys soon (hence my other thread about breakdown services!).

If it's any help - In order to get the sumps changed over I had to remove the exhaust system and the radiator. The bike is a 2000 Kawasaki ZRX1100 C4 with 40,000 miles on it.
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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[Bezzer]

If you can hear it when stationary get a mechanics stethoscope or put your ear on the end of a long screwdriver and go over the bike to find out exactly where the noise is coming from then you can take it from there.
I'll guess and hope that it is loose headers, they make a real tapping noise when they are. The bolts may be tight but did you replace the gaskets?, that would allow them to move even when the bolts are tight if they were old ones.
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I used to be indecisive but now I'm not quite so sure.

[KLR600]

I forgot to mention that I have a full Hindle exhaust system so I didn't need to take any of the collars off as the headers slide off the collars that are bolted to the engine. I didn't use any sealant when I slid the pipes back on but I did make sure they were seated back onto the collars as far as they'd go and re-installed the springs that held them on.

If it does turn out to be this causing the tapping would it damage the engine to do a long run (motorway, about 160 miles)?
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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[jimbothe]

So the bike was sitting with no oil in it at all for a few weeks?

I'm just trying to establish if it was completely drained and dry before I comment properly but it sounds like you're describing a tappet noise.

Is it similar to this noise? Forgive the fact it's a 250 ninja and probably sounds a lot worse than yours, it's the noise from the engine to concentrate on.

https://www.youtube.com/watch?v=y-ojHNiHUsc

Is it that kind of 'tap' or is it a 'tick'?

If tick then as already said, most probably headers not seated correctly or worn gasket.
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[KLR600]

Yeah it was pretty much dry for about 2 weeks. There was a bit of oil when I put a new filter in when I swapped the sumps over and there was still a bit of oil in the sump when I took it off but it was mainly empty.

It's a similar noise to that video but nowhere near as pronounced as that.

I will try my best to get a recording of it tomorrow if I can figure out a way to do it as I don't have a video camera.
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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[evoboy]

Ill take a bet its the manifolds not seated correctly/ exhaust leak.
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[KLR600]

I think I fixed it!

I took the rad and exhaust off again and re-built it all with a load of exhaust paste stuff and now it's stopped tapping.

Cheers for the help guys
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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[jimbothe]

Sweet
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[TUG]

[KLR600]

[StevRS]

If they're the same as the ZZR headers you're really limited to what will fit - and they're all bloody expensive!
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