OK, so you adjusted the chain BUT did you adjust it with you sitting on it? The adjustment is a 2 person job most of the time. It needs to have the proper adjustment as the owners manual states BUT with you weight on the bike.

00 DS
Ron Woods exhaust and CDI box
22 rear and 23 front ITP Holeshot XCT's

 

as far as tightening the large adjusting nut it can not be too tight as it will put too much preload on the tapered bearings and burn them up.i have found that hand tight until the play is taken out then just a little more seems about right.

 

MXZX- No problem. I just took it the wrong way. I'll check the rear end. I'm in the habit now of shaking the rear end from side to side now before every ride after riding with my raptor buddies. There axle nut loosens almost every ride. Yes, I adjusted the chain with me sitting on it. That 2-3" of sag from my fat butt on it makes a big difference. I've got it down to just me, just involves a lot of hopping off and jumping on. All of you who are replying, I do appreciate the help. It's always a plus to get some ideas before tearing into it and checking 90 different possiblities.

 

WRECKED, what it sounds like to me with this noise your trying to chase down is a normal condition for the DS. I know I have a noise somewhat like a rattle coming from the engine area on mine. It really started to bug the crap out of me. Mine is 2000 and about two months ago I had a buddy that bought a 2001. I was finally able to hear another DS at that point and heard the exact same rattle. Noises are funny things to figure out, especially when trying to describe them over the phone or on a message board because there is almost no way for another person to hear what exactly is going on. If I were you and your DS is still under warranty then take it to your dealer. Also while your there, have them fire up another DS and see if it does the same thing. And if it doesn't affect your performance or cause damage then don't worry about it and go out and have fun on it.

 

Call a dealer or bring your machine to a dealer and have them tighten the nut to factory specs. I don't remember how many ft./lbs. it took so I can't just tell you. It's been a while since I have had to work my DS, since I sold it and bought a motorcycle- KTM LC4 640. (now I can drive my wheels to work)