Thanks very much for the replies :-)
I've taken the magneto off and all looks ok, woodruff key etc locating fine and rotor seats hard down on tapered shaft ok. There are 2 washers, a normal plain circular washer(quite thick) and a very thick spring washer. I think that the very thick spring washer may be the culprit so I'm going to fit a thinner spring washer.........hmmm or thinking about it now should I just fit the plain circular washer and use thread lock solution ?
Many thanks
Paxo