by Knowledge » Sat Oct 03, 2015 11:09 am
Might this be the kick start plunger being deployed? If the plunger cam is incorrectly adjusted, then the two teeth on the plunger can hit the corresponding teeth on the first gear.
As a test, pop the rebound rubber out of the outside of the side casing, and start her up. If the noise has gone when the kick start is at rest, then it indicates that the ramp inside the chain casing should adjusted. It is an easy but not foolproof test.
Don't forget to refit the rebound rubber afterwards