Aaaaarrrrrrrggggghhhhh, I'm at a loss...HELP!!!

[Kickaha]

I pulled the gearbox down and again measured and checked everything

did you check each tooth on every gear to make sure none were missing or chipped?

[FzerozeroT]

mesh inside the oil filter slamming back and foward under pulse from oil pump? hey, you wanted random.

[**R1**]

did you check each tooth on every gear to make sure none were missing or chipped?

YUP, I spent 1 and a half hours stripping it and checking as i went, then i spent about 12 hours re checking everything..

[**R1**]

mesh inside the oil filter slamming back and foward under pulse from oil pump? hey, you wanted random.

I'll check....

And I'll also offer what little green bling I can give for the right answer if i ever find it.....

and if it takes much longer i't will be cash for the correct edumicated guess

[Ixion]

Have you checked end float on all the shafts ? Including the crankshaft. And looked for bearings moving axially in their housing under load, or bearings moving on their shafts? A knock that can be felt implies something faily heavy moving round.

[The_Dover]

It's not your nuts rattling on the tank is it?

[Dooly]

Engine mount/s?

[**R1**]

Have you checked end float on all the shafts ? Including the crankshaft. And looked for bearings moving axially in their housing under load, or bearings moving on their shafts? A knock that can be felt implies something faily heavy moving round.

Yup checked and re-checked, you can only just feel it without gloves..

[**R1**]

It's not your nuts rattling on the tank is it?

na bro it's not that loud

[**R1**]

Engine mount/s?

na, they were all tight when i took the motor out.

[beyond]

Only started when you popped the clutch?

Don't know the R1 but if the clutch sits on a shaft the shaft may be slightly bent or out of line and the new clutch is able to touch something when spinning cos that would make the knock faster as you speed up.

Hell, it's a tricky one mate.

[beyond]

Just one more thing. There are a hell of lot of forces unloaded when a clutch pops so all the bearings it sits in are ok now?

[beyond]

Did the knock go away when the clutch was pulled in??

Sounds very much like clutch bearings mate.

[Motu]

Have you checked end float on all the shafts ? Including the crankshaft. And looked for bearings moving axially in their housing under load, or bearings moving on their shafts? A knock that can be felt implies something faily heavy moving round.

Lay the bike on it's side engine running...both sides,and see if there is any difference - but I guess it's too late to do that now.I'd go for a bent shaft or a flat in a bearing ball - you've given it a fair bit of abuse,I'd be looking at things that can be damaged along the line of the power flow.

[Ixion]

Any of the shafts or bearings circlip located? When the clutch went it could have damaged a groove so that the clip is forcing out of its groove when under load, allowing something to move. But looks OK when not under load. Alternatively , a split ball in a ball race or a broken roller, they can be hard to pick up static.

Or something dmaged in the gearbox allowing a cogwheel to be thrown back and forth?

Sounds like it may be one of those piggish things that only shows under load.

No witness marks anywhere I take it?