The only time I have had a noisy gearbox, was with the BK2 because the kit idler (centre gear) gear was rubbish, once I changed that, it was nice and quiet.
I would look at that first, as I have never noticed a Kevlar spur gear to be as noisy as you are describing.
Bring it over on Sunday and I'll look at it for you.
As Danny also stated it could be your pinions, I had a few robinson racing pinions (silver ones), and they were noisy as hell, went back to my Trinity ones and it was quiet again.
If you do decide to change the spur/motor, do it one at a time, otherwise if the noise go's, you won't know which one was causing the problem (if at all).
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