I have a Diawa Tatula reel. Its about 1 years old. Casts great reels smooth. Everyting seems to be just fine except when I cast it makes a clicking noise. Doesn't do it every cast, about 75% of the time. I've torn it down, cleaned and lubed it, put it back together and no change. Everything functions and performs fine, It just irritates me when I cast and I hear a clicking noise. Any ideas?

How tight is the tension knob cap ?

If it´s too loose the spool can move sideways as it rotates making a clicking sound: tic-tic-tic

it doesn't matter how I adjust the tension. I can tighten it right up, or back it off or set it so it casts perfect and it still clicks. Sounds like there is loose line in the spool slapping during the cast. But I've respooled with new line and no change.

does it sound like a rotational noise? Like a rock in a tire?

I think so. The clicking/ticking sound is directly proportional with the speed of the spool.

But your saying that it don't make no noise when your reeling the reel?

Check the spool outside edge for damage.