VFR800 Fi Starter Clutch Problems - pics and video

Dear Sirs,

I am having a problem with my VFR. Some time ago it began to not start on occasion...all it did was click and nothing happened. This was temporarily solved by pushing the bike back and forth while in gear to 'unjamm' the situation.

I ordered a new starter motor but wasn't sure that he was to blame so decided to look into my starter clutch. All looked good, gears, springs, lock mechanism...

The starter arrived today and I started assembling everything back again. New oil (Jaso-Ma 20W50) and filter as well.

When I tried to start the bike it started right up but the strangest noise came from the engine. I suspect misassembly of starter clutch but want your opinion. The following pictures describe my assembly procedure for your evaluation. I did all this twice with the same sound as result. The manual isn't as clear as it could be.

1 - Pushed the first pair as far as it went:


2 - This part is showing some damage / wear - I think this may be where the noise is coming from. I don't understand the function of this part. it does not snap in the next one...


3 - Placed


4 - Place clutch and push as far as possible


5 - Place 'timing circle' - it doesn't go all the way - this seems strange. Torque to 106nm as per manual


6 - Place idle gear and oil the whole assembly


Now a little clip of the sound produced - Not for the faint of heart:
https://www.youtube.com/watch?v=PsLJzJw7iyw&feature=youtu.be

Many thanks for your help...this is eating my spirit away...
Paulo