1978 cb550 rattle under load. Any help?

DaveBarbier - Looks good, looks like what I've got.

Been doing a lot of check on this thing, just about everything possibly and every adjustment. Then...

Here's something interesting. Do you guys think that's a bit excessive of movement? Indirect evidence that the primary chain has a bunch of slop and needs replacement?

https://youtu.be/MaKgBn279jo
 
That play looks kinda normal. If you haven't yet, drop the pan, then you'll be able to see if there's any metal debris & if the primary chains are rubbing the cases.
 
YOU CAN'T CHECK PRIMARY CHAIN SLACK LIKE THAT oops dint meen t yell :)
anyway there is too much slack in the gearbox, the engagement dogs to be specific,to get any idear....
you need to gently rock the crankshaft back and forth and watch for delay in movement of the clutch.that is the only way you will see actuall primary slack
maybe you can watch the clutch thru the oil fill port
 
Sounds to me like valves were adjusted on overlap, plus the cam chain was adjusted wrong.
You don't loosen the nut that far.
If you want to see tensioner 'working' rock crank back and fore a few degrees with the nut 'loose'.
You will see threaded part rotate around 10~15 degrees. Don't go too far though as it IS possible to make chain jump a tooth on cam sprocket. You can turn motor in 'correct' direction, watch 'bolt' rotate then nip up the nut (the 'bolt' has a half gear pinion on head)
 
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