1st post so bare with me. I have an 03, Kat, 750, has about 11,000mls, The motor has what sounds like a chain rattle in gears 3-6 mostly between 3500 -5000rpm. Bike starts fine with no noise, kinda think it might be the cam chain tensioner but looking for other ideas!!!
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I have a similar noise from 0 - 80
My chain ran loose and rubbed the rubber guard off of the fron of th eswingarm, under load the chain is pulled tight and down onto the swingarm, when I clutch it and coast; the chain relaxes and lifts up off of the swingarm making the noise go away.
A good test is to remove the chain, put the bike up on the center stand and go throught the gears, if the noise is gone, check the front of the swingarm and replace that guard.
Hope that helps...
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