Try our new info resource - "Aladdin's Cave" (Main menu)Just added a separate link to Ash's Dropbox thread (shortcut)
I'm thinking the woodruff key has moved as part of your troubles - I can't see the crank being bent given the circumstances. It's definitely a mystery it will be very interesting when you finally locate the cause.
On the inside of the starter cog is a bronze bush, it is easy to see it that is damaged You have done this a little arse about face as, you should of taken the fly wheel off before splitting the engine
Ok learning a lot here.Managed to get the generator nut off, just waiting for the puller tool now.Although the starter gear is now behaving more correctly (it didn't spin any direction before, only just realised that wasn't normal!) I assume there is still something wrong? In normal operation is that cog free to move a bit latterly. I assume it's not meant to be able to rub the case if it wants?