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[Wheaters]

I bought a simple stethoscope to help pinpoint noises like this. Very useful.

[stinkwheel]

There is a definate element of alternator noise there. May not be all of it but you can hear a slighty graunching whirr when you move round to the left side like you get with a loose rotor or badly spaced stator. If it's that, it'll get louder when you put the headlight on.

[grindstaff]

Thanks SW, I'll investigate that today.

[grindstaff]

Everything seems to be correct under the cover, I think I'll only know if I dismantle the top end, which I really didn't want to do. Oh well.

[vince]

Hi, tou said it all appeared correct in the primary case but did you check if the alternator key had sheared? Vince

[grindstaff]

Yes, the rotor was firmly attached to the shaft, no wobble or movement, no metal in the oil.

[grindstaff]

UPDATE: I took off the head and barrel as I was convinced it had to be a worn small end. I first found valve guide oil seal from our hosts then a brand new piston and new head and base gasket. Small end was perfect as was the big end.
I put it all back together, reset the tappets ever so slightly tighter (they still spin freely), started her up and the noise is gone.

Thanks to everyone who made suggestions.