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New crunching noise

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Thats rite, my 2002 plated e with about 2,500 hard miles on it just started making a pretty nasty crunching noise in the top end while breaking in a new motorcross track. If I had to pinpoint where the sound was coming from I'd have to say the left side of the bike. It's not a constant sound, does not have a rhythm to it or any thing like that, but it be heard every 10 or 20 seconds at idle. It almost sounds like a rattle or when our motors shut off and take that half turn backwards. I already checked the stator to see if the bolts had backed out, but that whole area was tidy as when I did the loctite fixs. Valves where checked and in spec 500 vicious miles ago, oil changed to 15-40 ester based oil about 70 HARD offroad miles ago. I still have the ACCT so I'm not ruling that out, other than that the only other thing I can think to check is the starter...The bike is running amazing rite now and the sound cannot be heard nor felt while riding it. I'm stumped and trying not to chew my greasy nails rite now, someone splease shed some light on me.

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Might be worth pulling the valve cover off and just looking around. Post pics of the cam chain on the cams.

If you think it might be the starter, take the wire off the starter terminal and let it run. Although I'd be scared to let it run with much of a noise.

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I could very well be mistaking this sound for a rock randomly rattling around under the skid plate, it just does not seem likle a common top end noise. Guess I need to check the cam chain to see if its loose...I thought the ACCT made them run to tight though..

Oh and the starter shaft seems to have the slightest bit of play in all directions.

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...I thought the ACCT made them run to tight though..

The 2002 models had the early ACCT where the failure mode was that it let the cam chain tension go completely loose when the cam chain tension on the "slack" (adjuster side) went too high - like under hard deceleration. Suzuki "solved" the problem with another version with a ratcheting mechanism, but it applies too much constant chain tension - prematurely wearing out the cam chain.

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