The matter is now resolved, hopefully permanently. After googling it I went in this morning with a raging hangover to look for damage. None. Nothing anywhere, the teeth were perfect, everything was fine. Then we found it, the bearing that the actuator arm runs in had moved. Knocked it back into place and the vibrations are gone, the clutch is silky smooth. I have no idea how it could have moved in the shipping crate. My only guess is that the spigot that comes out of the top of the housing was pushed hard in the opposite direction by one of the guys building the crate (or me, I guess). The design of the clutch and this basket is identical to the BMW G650gs/F650gs so i guess this could happen to them too.
BMW have replied to my emails about the recall work and are looking into it for me and I think it's best to pursue it and try to get this unit replaced before it happens again. In any case, the bike is purring and i'm a happy little Jack. Thanks to everyone who would have replied and I hope my experience has been of some use to others.
Last edited by Jtw000; 26 Nov 2011 at 09:31.