Loud tick noise in crankcase.

Without being able to stand next to the machine and listen it would be very hard to say what the noise is. Valves are generally easy to adjust and if loud have a high pitched tick sound. Cam chain adjusters generally self adjust and are reasonably quiet. If the automatic adjuster goes bad it will generally make a clatter sound or a loud clack. One thing you have not considered, if the the exhaust gaskets in the head go bad or leak air, they can also produce a loud ticking sound. You often hear this sound in older V8 engines. It sounds like a lifter is bouncing around inside the motor but the sound is caused by a blown gasket between the head and exhaust manifold. If you experience some popping/backfiring during deceleration try replacing your exhaust o-rings in the heads. This may solve both problems. If the problem is internal to the cylinder you may need to change a bad cam chain adjuster. As always start with the cheaper fixes and work your way up. Adjust valves and cam chain tensioner if not self adjusting, replace the exhaust gaskets next, and if that does not fix it, replace the cam chain tensioner. Hope this helps.

The timing chain tensioner is self adjusting.....Here is some info you can read...

All the parts in your engine are wearing in. Part of the 600 mile check up involves adjusting the valves and the cam chain tensioner (if it is not self adjusting). Chances are the valves are wearing in, the gap is too wide, and just need to be adjusted back to the correct clearance. Worst case scenario the cam chain tensioner has failed. http://www.kawasakiforums.com/forum/general-tech-9/klx-250s-2006-loud-clicking-sound-not-valve-33671/

For most vehicles it usually means a lifter out of adjustment, I have actually heard
a timing belt do this as it began to fail (if your vehicle has over 90 thousand miles)
Both items would require a visit to the auto repair shop. I hope this is useful.

You can purchase a maintenance manual for your bike here - http://www.tradebit.com/tagworld.php/rmz450 They charge 10.95 for the book. There should be a manual chain tension adjustment using allen wrenches, but you'd do well to get the book and do it the Suzuki says. Otherwise, you could wind up with a broken chain or jumped timing to reset.

When correctly set, the valves can be quite loud on startup on these bikes, sometimes described as the "angry sewing machine". I would prefer that they be to the "loud" side than too quiet, as a tight exhaust valve can cause it to be burned from prolonged contact with the seat. The tensioners have been subject to fail- not universally, but it does happen- and that will be more of a knock from the side case that a rattle. The tensioners are self-adjusting until worn out.

Kawasakis of this vintage have an automatic cam chain tensioner so the timing chain adjustment is not likely the problem. The chain itself may need to be replaced however, which is not a difficult job for a mechanic with a shop manual to follow the proper sequence and reinstall to specs. Otherwise, you may wish to seek professional help. If you do, ensure the mechanic knows Kawasakis of that age group.

No I would not chase to the pistons, these vehicle were very comon in creating HLA noise hydraulic lash adjusting valves, meaning the valves pump up with oil as the oil gets thinner they dont pump up as fast and create a very loud ticking noise, I would not express a great concern over simplicity, dodge was famous for this, they really were.

if this charger has the 2.7 l engine the clicking noise can be timing chain or timing chain tensioner imedate service is required timing chain issues can cause internal damage to your engine

I put my piston to toop dead center and readjusted my cam chain and it seems to be running fine. The only thing I had to do was to turn the idle up a notch which still kind of gets me....but it's better now.