I agree on the note stealing polyphony thing. I think the logic of the DSP is taking notes that have a long release and taking them before they fully release, causing a DC click. Like when you cut a sample of a kick when it is not at zero crossing.
If you notice in single mode when you change patches from a patch that has an long release or a long reverb the DSP will fade it out quicker that the patch would normally do so. In multi mode or seq mode the DSP has to do this a lot more if you know what I mean.
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