Hello, im a new member here and here my first problem.
Firs of all, This is what i have right now!!! Please take a look http://www.youtube.com/watch?v=8Ojt1_4iC5U

So in an attempt to fix it, i first checked the CCT, which turned out to ber in one piece and i alos tightened it a notch. Started it back up and i get the same noise. So i take the clutch basket off and OMFG!!!!! I see weird metal pieces sticking out from the plates!!!! (pics below) So i start counting... It turned out that the frikkin poser-mechanic put in one exta plate in there. The extra plate was behind the last (Inner-most) metal disk touching the aluminum clutch assembly. And THat damn plate broke into pieces and some of the pieces are missing. So i was like alrite. Ill take out what metal i can find and put it back together. So i do. And the noise is still the same. So right now i have the oil pan off (i thought maybe there is a big piece of something in there or a rod knockin). And i dont know what to do.

Please mates, listen to the video and give me something to work with. Thankx. Here are the pics

 

http://www.youtube.com/watch?v=uOzJMrqLAXg

heres a look at the transmission just by itself. lookin through the bottom of the engine. Is this the noise?

 

could be. feeler gauge the engagement dogs to check the gap. if the noise your getting is just from spinning the clutch hub, then you've got a problem solely on the "input" shaft, and not the counter shaft..

i initially thought "rod bearing" but seeing that it does it with the input shaft free spun, i'd say bent shift fork, or wiped bearing. almost looks like you can pull the forks and shift drum right out without engine removal or case splitting. if you can, i'd do that and measure runout on everything, inspect bearings, axial/radial play on gears.. ect.. run the entire list on every part.. you might be lucky and have a piece of plate stuck somewhere. lets hope so!

good luck, keep us posted, and welcome to KF!!

 

Do you see any where "behind" the clutch basket for scratches to indicate where the loose pieces were hitting? It could be that the spacing collar (should be on the shaft, behind the basket, against the bearing) is the wrong size, or (common inn shops) missing. And the back of the basket is hitting something...
That's best guess...
also check the riveted sprocket on the back of the basket for marks from rubbing, and look closely for cracks. Especially around the rivets. That assembly must be tight...