The yellow is again clicking this morning - so it seems even more likely your explanation is right.  There is something "wrong" with this spool for whatever reason.

After my original post I pulled out my Clear Yellow and reinserted my clear.  I printed a 1/10th scale cooler, lid and drum.  Some minor clicking but it was only in two spots - when originally laid down and then once mid-print.  On a whim (after reading a post about the tension lever on a 1.0 being too tight) I pulled back on the lever as if loading and heard an audible "click" - after that no more clicking.

The clear printed all three objects perfectly without issue.

This morning after reading your post I took the calipers to my spools - Black was 1.68, clear was 1.66 and the Clear Yellow was 1.57.  Certainly seems to be off on size.

This morning I'm going to try one more time with yellow and if it clicks relegate it to the "bin" and simply get another spool and see what happens.

Thank you again for the quick response.

Yesterday I loaded a clear yellow spool.  Started an overnight print of an object that would take up the full bed.  Overnight I could hear the stepper motor clicking.  I had heard this ocassionally on the other rolls but saw no obvious ill affects and simply "logged it" as a possible need to check the X and Z axes.  But it didn't seem to be consistent or an issue.

Anyway, I woke this morning to a non-print and just garbage on the bed.  Tried to print something else and noticed it was not laying down right.  Tried again this evening on a small item and same thing - clicking steppter and gaps in the print.

Switched back to clear - and nada - no clicking and a good print.

I cannot find a direct correlation thread anywhere so figured I'd post and see if anyone had any thoughts.  At this point I'm wondering if this roll of clear yellow might be too large?

Thanks