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It looks as though the chain roller catches on the tooth of the cog as it moves off...
I has the same with a brand new set-up.
Charlie the Bikemonger was a stumped as I was and refunded the sprocket, returning it to Surly under warranty.
Surly accepted it, noting that it was a problem they were aware of in certain circumstances, but wouldn't be drawn on what those circumstances were.
Looking at the profile of the teeth, they were wider at the top compared to other sprockets, ie not pointed.
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Dirt on the spindle/crank interface or bb cartridge/shell with dirty threads?
Or any of the above and associated bolts not torqued enough?
Do you have a quick link in the chain? A slightly bent link plate causes me weeks of WTFs.
Scilly.Suffolk
miro_o
@NotThamesWater
My chainline is making a noise near the sprocket like a dishwasher full of spanners.
The sprocket teeth (surly 1/8 17t) looked to be worn, with play between the rollers and the teeth.
The chain itself is pretty new, and I have replaced the sprocket.
And it's still ridiculously noisy.
It looks as though the chain roller catches on the tooth of the cog as it moves off - which would also explain the wear pattern on the old sprocket.
What am I doing wrong, internet?