Flushed with success with my starter mods I went out this morning to see if it was still starting. Yes it was. However, I noticed that when the starter operated the primary chaincase was moving about! Closer inspection shows a gap between the back of the chaincase and the crankcase. I believe there are some countersunk screws supposed to be holding it together - hopefully they're just loose or indeed missing rather than stripped. Actually it's a good job I noticed as if those screws escaped they could cause further mayhem in the primary drive.
Starter assembly, stator and clutch now removed and retreated to the house to ponder!
I probably should have realised as there were other parts just loosely assembled but it all looked OK with a superficial look over.
Illegitimi non carborundum
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Now all in bits...
... and the thread on one of the threaded holes in the crankcase has stripped, the other screws were just finger tight so a disaster waiting to happen. After mulling options I think I'll make an insert out of a cycle thread 3/8" setscrew, appropriately bored and tapped 1/4" BSW then loctited in place. There seems to be plenty of meat around the hole and I don't really want to spend £30+ on a helicoil insert kit for one job. I've done similar before with good results. I know ideally Cycle is too fine for alloy but it'll be a fit once and forget job, plus the thread depth is less than say BSW so giving more meat for the internal thread.
I'm taking the opportunity of having the primary off to fit the 20 tooth sprocket I bought earlier in the year. Fortunately before trying to get the nut off I checked the manual to discover it's left hand thread. I think I'll probably need a cranked link in the chain as the adjusters are pretty much at their full extent.
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The above dog Latin phrase sums up old (and, sometimes, new) British bike ownership! Keep at it, you will eventually win! As Wniston Churchill was fond of saying, KBO!