OMG Another issue........ Ideas?????

[dastardly_dog]

So.....A new problem just popped up. when I rev the engine in neutral problem does not exist. When I rev the in gear I cant tell. When clutch is pulled in problem does not exist. On down shift with clutch out I hear a grinding sound. Checked wheel bearing by coasting with engine off. Sounds OK. I feel slight vibration when I touch the clutch cable on top of engine that matches grinding noise. I just tightened the chain but not sure if this would cause grinding sound only on down shift. It sounds like wheel bearing grinding if you can imagine what that sounds like, but I know for sure its coming from clutch rod area. The fun never ends with this bike.

[gsJack]

A badly worn front sprocket will make noises like you describe when coasting in gear at lower speeds, most prominent as you come to a stop.  Front sprocket is in the clutch rod area you describe.  If you have a 89-93 GS with front sprocket without a hub just turn it around and see if the noise stops.  Always helpful to mention year of your GS when posting about isseus.

[dastardly_dog]

Thanks for the info.....I'll check it out today and reply. btw, It's a 96 GS500e 

[dastardly_dog]

Answer found Thanks..... Long story short was "chain tension" to tight.....

http://gstwins.com/gsboard/index.php?topic=12716.msg107480#msg107480