Thanks for the suggestion - did that and no sound
WIth further investigation, I've noticed the sound is almost exactly the same every single time. As the motor dies, there's two noises, click, click about 1 sec apart. I think it's one of the brushes on the roller catching something. But quite what I cannot tell, and why I can only hear it when I stop it is another mystery.
I salvaged the brush bar off another DC07 that the motor had failed on - I may need to try taking the bits that fit around the roller off it too and see if it makes any difference.