Hi all,
In hindsight I should probably have made one big topic instead of several smaller ones but oh well - at least my problem topics might be more easily found on google so who knows it might help someone

.
Anyway, yesterday while (succesfully) checking for oil pressure from the oil bleed I noticed a clanking sound that wasn't there before when turning over the engine.
I already saw doomsday scenarios but then realized the sound was coming from the starter clutch.
When I removed the spark plug, the sound would disappear. I opened the flywheel cover and saw why. Cranking by hand, right after TDC compression stroke, the starter clutch would get a 'shock' and rotate backwards for a bit. It would then hit the smaller gear which makes a huge clunking sound.
Both my smaller gear and the starter clutch gear have huge play on them. Is this normal?
I can move the smaller gear 0.5mm axially (as if a spacer is missing) and the big starter clutch gear more than 1mm. I didn't forget the spacer ring behind the starter clutch gear, and flywheel is torqued to 120nm.
Basically I think I have this problem , only in my case, it goes away when engine has started:
http://www.horizonsunlimited.com/hub...learance-97481
Well, knowing it's "just" my starter clutch, I went ahead and tried starting it anyway, and to my surprise it started almost right away


Here's the video from the first start:
https://www.dropbox.com/s/sxrqwhjwpg...0001.mp4?raw=1
In the beginning you can hear the starter clutch clunking away. After start it goes away and it sounds great.
Thanks everyone for helping out