the chattering is normal i had posted about the same problem and even brought it to a shop and they said it was normal

 

I have a '97 F3 and have the same type of problem, the clutch has quite a bit of freeplay, weird part is it seems like the more free play it has the quicker it engages when you're letting the lever go. Is this normal? Should it have to be almost all the way out for it to engage, a Honda service guy said it was normal but seems weird. Thx

 

I don't completely agree with others on this thread. The chattering you may here during engagement could be the fact that the clutch basket has worn tabs were the plates create pressure against the tabs. When you dismantle it, look for ribs. You can file these ribs down and this will help to reduce the chatter. Also, look at the springs. With that many miles on the bike, and assuming the springs are stock, you could consider getting a slightly stiffer spring which will move the plates a very small distance and that would reposition them on those ribs I was mentioning. Last, you could consider running sythetic oil too. When replacing the friction plates, I would replace the steel plates too. There's a chance they could heat up and warp. How I found this out was when I use to race motocross. I know your doing alot more shifting in motocross, but if your hard on your shifts when the bike is at operating temp, there's that chance again.

 

I just bought my cbr a few days ago and when I was riding today I learned about the chatter. It's weird because when you first start the bike and it's in neutral--no chatter. But if you've been riding and you throw it in N at a stoplight, you can feel the chatter.