That's one of those things that happens with a pin or a bearing slightly out of line and getting pinched. I've done that before and pulled the thing apart - couldn't find anything but for some reason known only to the gods of winches it worked fine when it went back together.
As you say - it won't be much but it's really frustrating when you can't work it out. There will be a pin or a bit of the lever that isn't sitting right in it's mating slot and when you engage the clutch it will be pushing the works out of line. I wouldn't consider myself a winch expert, but have destroyed and rebuilt several that gave up in the line of duty hauling crap out of the way of underwater structures and pipelines.
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