youtube.com/shorts/u3SONQjuERc?si=1jTv9KDR3Tx6kLg7

On a separate note, this is the audible click I can get from the rod bearings, is it acceptable or should I tear I apart immediately ?

I save it & slowed it right down, expanded it up big then lined up the top ring with stud then & also tried to eyeball the rod down at the flywheel.
Turned me hearing aids right up & its very audible but i'm buggered if i can see movement coinciding with the clicking at top or bottom.
I know i'm blind & deaf but is it side movement & not up n down. Hope someone else can see it.
I guess it is up & down & none is better than some.
A new assembly would have zero movement but would have some sideways like 10-15 thou but you'd have to be moving it sideways--which you aren't obviously doing.
If you pull the piston off, how does it feel to revolve.
Might have to pull the flywheel to stop magnets making it difficult to revolve uninhibited.
Any roughness to feel via the rod while turning is indication of a hardening issue on pin & rollers.
Any change in feeling of clearance etc.
Sorry to open a can of possible worms.

Better a can of worms than an imploded motor !
I did try with the barrel back on and see if I could feel any up and down when pressing on the piston top but almost imperceptible. I think I’ll try getting it running with the new kit and then go for a midwinter tear down.

The kit fired up and running straight out of the box, need to give it a run now and see how it’s jetted.

I stripped out all the old electrics and headlamp and replace it with a 12v LED sealed beam, just waiting for a connecting block to test it. I’m thinking the oil feed is a bit high, any advice on how much smoke I should see at idle greatly appreciated.
youtube.com/shorts/RRd-NY-wtCk?si=wb7Y3EzKuBwUNNCa

My advice is to ride warm it up and ride it hard for a good long while before trying to assess "smoke".

Also, jetting and oil types are a factor. Modern synthetics usually won't burn that well.

Someone’s on here had a saying at the end of each post,
“If it’s smokin’, it ain’t broken”.. great words, for 2 strokes.