YouTube videos got me scared so I made one of my own... I've got a 2007 s40 with 19,200 miles on it. Bought used from orig owner at 7500 miles with this aftermarket Harley pipe already installed. Trying to put off big project (new Dyna pipe, spark plug, petcock, rear blinkers, verslavvy) until May. Please listen to videos and let me know, would I be taking a big risk commuting on this bike for another month?

http://youtu.be/UDgECFmzo9I

I have a hard time discerning the cam chain noise on most of these vid's.
but let me feel or listen with a stetho and I'll tell you right away.

feel down by the oil filter cover, just to the rear at the top of the clutch cover.  If you feel tapping, it's close to going.  This is not 100%, maybe 95%.  sometimes the adjuster will go up and lock against the case.

We need someone to fabricate a small plexiglass "peep hole" for us! You know, kinda like the oil level window.

Putting it off is, IMO, very dangerous. Were I you I'd be getting the gasket and tools and gasket goo and a Verslavy and walking off in it, before you find yourself walking away from it.
We've seen them fail at much lower miles. The physics of the failure, average miles ridden per trip, how hard we ride, mostly conjecture, but the consensus is that it matters. The collective knowledge here is way beyond what you will get from the shop.

If you think tackling it is a hassle, wait till you see what not tackling it looks like. I know of one who let it go too long and didn't ruin the motor. The others were hunting for used motors.

If you even suspect that you're hearing the chain at 19,000 miles? I would be afraid to even start it.

The really important part, the added length and additional hole, can be done pretty easily. The drilling, slotting of the case, roll pin installation so it Can't extend further, takes some doing,,,
Verslagen is the guy..

I have the gasket and am only worried about the hassle of doing the job twice because there is a significant wait for verslavvy at the moment. If I open it up and see it's in bad shape, I've got parts laying out and crap to keep clean laying around my basement for 2 months.

Say I open it up and it's 20mm out, is there a temporary fix to keep me chugging along til May?

Alrighty then. Gonna drain tank and put on raptor petcock and will put this project off til may. Felt a little bit of tapping near rear of clutch cover.
Guess I'll get my 78 Batavus regency going again. Thanks for your insights all, I appreciate it.

Here it is all opened up.