Thanks mate I ordered two just in case.
Fitted it and it seems to be running fine.
Turns out the cause of the issue (I think) was the small grub screw that holds the pinion gear in place was loose from the factory, so it was allowing the pinion gear to move in/out and obviously become offset against the spur.
Had a good run on a full battery and the grub screw has come loose again and it had just started to shave a tiny amount off the spur again. Need to get some threadlock I think.