When I shift into gear (both on and off stand) and engage the clutch while in gear I hear clicking sounds coming from near the output shaft. The output shaft seems to "jump" for lack of a better term. Its not a consistent thing with rpm and if I spin the transmission with the clutch plates removed I can't hear it while in gear. I have inspected the clutch basket and plates and all is good there. I have a new chain and sprocket kit. The noise and jumpy-ness is also there with or without the chain on. The clicking usually starts around engaging the clutch 25% and continues even to 100% engaged.

Symptoms
-Clicking noises near output shaft
-Jumpy/jerky output shaft
-Consistent in all gears (except neutral)

When it happens
-any rpm
-in any gear (except neutral) with at least 25% clutch engagement
-seems to happen whenever, not consistent with a certain spot on the output shaft
-with or without load on the output shaft (chain on/off, bike on or off stand)

What I have tried
-Inspecting clutch plates and basket for grooves (Minor grooves, but nothing to write home about, seen worse, bike has 24,000 km on it)
-new sprockets and chain (rebuilding the bike, as its a project bike)
-Tried in every gear while on stand
-Tried in first and second off stand

Any help/ideas is greatly appreciated, I believe I'll be splitting the engine apart to fix it, but would like some suggestions on what to look for before I go too far.

Thanks in advanced for any help.

 

Have you inspected the spring? Does it have the needed tension?
I remember somebody else having this issue a long time ago, and they swore everything was as it should be. When they created a video, it showed them manually manipulating the lever that the clutch cable connects to, down at the clutch case. We pointed out to him that there's no way he should be able to do that. It took a bit of convincing but he finally swapped out the spring and it solved his problem.

 

The spring for the arm or the 5 clutch springs that get bolted down?

I cant manipulate the Lever by finger, only by the clutch lever, I'll attach a video of what its doing. Although to add some more tension to the springs I could attempt to stack a small washer under each spring to simulate more tension.

I am unable to upload directly but I'll upload it to youtube, its the clicking and clattering thats heard. And when the chain is on it seems to what I can describe as jutter the spring hard.

 

In the case to which I was referring, it was the 5 springs that get bolted down.

 

Ah ok, I'll try putting spacers in there and give them some more tension and see how that goes. I'm thinking it is clutch related because when I have the plates out and spin the transmission in gear by hand there's no clicking or anything.

Thank you for the suggestion/idea to try. When I'm back at the shop with the bike I'll try it.