Thanks guys I won't be changing the hub bush as I only bought it thinking there was supposed to be another bush on top of that one because the one in the video can be removed with a magnet.

I think the bush is (only) there because of manufacturing purposes, its easier to make a hole troughout the whole shaft and then put a spacer in it.

Edited March 31, 201511 yr by crazybond700

I've put it all back together with new idle gear kickstart gear but the knocking is still there.

Any ideas?

Edited April 9, 201511 yr by craigrevo

The broken pieces travel to the primary gear on the clutch. They become smashed between the teeth and sound like a rod knocking. It can be very hard to find. Try using a magnifying glass, and go tooth by tooth.

My primary gear had this. This is the gear on the crank. It had a very slight knick. Lukily i had an extra around to isolate. Take a nail file to each side. Fixed me up.

--Biff

Mine had it too. Also the primary gear (right one of the clutch).

Than it probably needs new clutch basket and primary gear. But try too isolite the problem first.

Is it safe to remove the clutch basket and start the engine to try and isolate the knock? If its still there it rules out the gearbox side.

How would you want to start it?

Doh!!

I've got it apart again and I'm convinced it's the bearing that holds the clutch basket now as there is rubbing on the clutch case that I put down to old marks before. As there was no obvious signs of metal flakes, but tonight I opened the clutch pack again and there was loads of alloy flakes trapped in it.

Edited April 16, 201511 yr by craigrevo

Now this peace of crap is annoying me!! So far I've spent £400 on parts and still it's knocking. I've replaced

Kickstart gear

Idle gear

Clutch basket bearings

Clutch main case bearing

3rd gear half bearings

Output shaft bearing

Flywheel keyway

Crank case main bearings.

There is about 2mm of out and in play in the clutch basket but i don't know if that is normal or how to fix it if it isn't normal.

I've removed the water pump and the knock is still there, so that can be ruled out totally now.

This thing is driving me mad.

Got it!! There was a tiny dent on one tooth of the clutch basket.

So I have used a dremel to reshape it.

Now it sounds loads better!!

Thanks for all your help and advise guys.

Yeah, small bits off can cause lots of noise!

Well done on finding that Craig!  That must have been damn frustrating. Hope it's all good now.

At least now I know the engine is good with all the new parts, and I know what to look for in the future. Ive ordered some new shims for the gearbox to take out the slop and hopfully I will get to ride it a bit.