ahh good theories..
I just assumed maybe the metal fingers were breaking in.. as I could not source down what in the world was wrong with my setup.
I am running a stainless steel clutch line, so I hope there is no ballooning...
as for the chatter, I have not had ANY chatter after the intial 1,000 mile break in or so .. but the directions indicated chatter is common on initial break in.
I checked the fork when I pulled the engine out 2 months ago, no cracks, or bends. I remember reading all the threads about ACT clutchs and seeing a pic of the fork BENT! jeesh! so I checked it out.. no probs
Weird thing was I ran a NEW master cylinder and a NEW 11/16 slave cylinder at the same time, and still had issues.. no air bubbles or anything...
thats when I gave up, returned the master and bought a 3/4 and life was good.