'06 Honda Rebel 250 rattle from stator/flywheel side after overfilled oil blew crankshaft seal (video included)
Hey guys, looking for some insight on this rattle on my 2006 Honda Rebel 250.
Context on how this started: The bike was heavily overfilled on oil by accident and got really hot, which built up crazy pressure and violently blew the crankshaft snout oil seal completely out of its seat. I took everything apart to fix the leak, but ever since reassembling, I’ve had this persistent mechanical rattle.
I’ve had the flywheel off 4 times now trying to get this right. Here is exactly how it's currently put together:
>The starter sprocket and flywheel were bench-assembled (twisting past the rollers) so everything clicked in right.
>The whole assembly was slid onto the crankshaft snout together on a good woodruff key.
>The main flywheel bolt is fully torqued to spec at 33 lb·ft using a chain strap wrench to hold it.
The engine idles completely smooth and steady with the choke off, but the rattle is super clear at low idle. When I give it gas or pull the choke to speed it up, the noise seems to go away or get masked. Also worth noting: when I pulled the flywheel off one of the times, one of the starter clutch rollers completely fell out like it was loose.
Airbox is bone dry, and the oil didn't look foamy when it originally leaked out. What am I missing here? Did the extreme heat/pressure warp my starter clutch housing, drop an idler gear bushing, or is it something else entirely?
Any help is appreciated!