When you need to see the parts moving to find the problem, get a helper to turn the flywheel, very gently, until it stops. Then have your helper turn the flywheel backwards until the knotter begins turning, then turn it forward again until it hits the obstruction. Repeat this over and over while looking at every moving part. Sometimes you can hear it when two parts make contact that are not supposed to. Since the clutch will not turn the knotter shaft backwards, you will need to clamp a pair of vise-grips somewhere on the shaft so you can turn the shaft backwards as your assistant turns the flywheel. My first thought was the plunger lock, but you specifically said knotter shear pin; but the plunger would have locked long before the needles got that high in the chamber. Also bothers me its doing the same thing after changing the knotter assembly. Without being there to see it we are kind of shooting in the dark, but I think rocking it back and forth against the obstruction you will eventually find out what is hitting.
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Today's Featured Article - Earthmaster Project Progress Just a little update on my Earthmaster......it's back from the dead! I pulled the head, and soaked the stuck valves with mystery oil overnight, re-installed the head, and bingo, the compression returned. But alas, my carb foiled me again, it would fire a second then flood out. After numerous dead ends for a replacement carb, I went to work fixing mine.I soldered new floats on the float arm, they came from an old motorcycle carb, replaced the packing on the throttle shaft with o-rings, cut new ga
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