Looking for advice on clutch center backlash!

I've owned this bike for the past 8 months and it has always clunked really loud when leaving a stop while actuating the clutch...makes the same noise when you're in first gear and making slow speed maneuvers without the clutch disengaged (i.e. slipping).

I previously thought the clutch basket was worn, but I had nothing to base this one except my gut since I hadn't taken it apart at that time. I finally got it apart tonight and to make a long story short, the clutch assembly is definitely worn, but it looks to be within the service limits (31k on the clock). The problem I found is that there is about 60-70 degrees of backlash between the clutch center and the drive wheel. In other words, the clutch center can rotate 60-70 degrees before the chain drive rotates. I'm nearly positive this is the source of my noise/clunk. The factory service manual doesn't list a backlash requirement, I'm assuming because there isn't supposed to be this much. Has anyone else experienced this? How much is 'normal'? I'm wondering if my tranny is toast now...HELP!

 

It would be helpful if you told us the year and model of your bike. I know that some owners have installed am aftermarket shift star and detent arm kit with good results.

Factory Pro Shift Kit

 

Sorry all, the bike is a 99 800 with about 31k on the clock. Also, I should have specified that the chain is totally spent and needs to be replaced. I haven't had a chance to check (I should have before posting, sorry), but I'm wondering if the chain drive being so sloppy caused the countershaft sprocket to wear. Is it keyed or splined to the countershaft?

 

A worn/sloppy chain can definitely cause a lot of driveline lash. If your chain is very worn, inspect the sprockets carefully as they might both need replacing as well. It is best to replace all three at once. You will especially notice a lot more lash when a chain has a lot of kinks in it. You should notice a big difference once you have a new chain and sprockets on.

Yes, the front sprocket is splined on the engine drive axle.