This is my first time working on a motor so please excuse me if I am not clear and concise.

My problem is the starter will not work all the time. When it does, the motor starts quickly. The battery and solenoid are new. When the starter does not work, I can feel something binding when I try using the recoil starter. One or two pulls on the recoil starter and the binding disappears. After that I can start the motor with one pull using the recoil starter and the starter also works. I have lived with this problem hoping to get a clearer picture of the actual problem. Finally I pulled on the recoil starter and it would not budge. Thought I would break the rope.

Today I removed the flywheel looking for a problem. The one way clutch appears to be fine. The starter motor rotates freely and works on the bench. No metal particles were found and all the starter gears look new. The only possible problem is the big starter gear appears to have too much movement and you can see some slight wear on the casing. The bearing for this gear seems to stick out approx 1/32 to 1/16". I was thinking any movement (cannot measure) of the small gear and shaft that meshes with this big gear may allow the gears not to mesh. There is also a slight taper on the teeth of the big gear which I do not understand the reason. I could add a shim between the big starter gear and crank to take out some of the movement but this is only an assumption and the work I have invested to this point requires something more definite. I might add that whatever was binding is gone during my disassembly.

My next step is to open the front housing and check for a problem with the clutch but I haven't a clue. I fear I will have a pile of parts and not find a problem. Any help will be greatly appreciated.

 

Removed the front crankcase cover and everything looks good. There were no metal particles found,the centrifugal clutch moves freely and the one way bearing works. The centrifugal clutch housing does show discoloration from heat. Is this normal?

 

It can't be the starter or the shim since the binding is happening when you pull the recoil. I was going to ask if there is possibly too much oil in it but I see that when it starts it runs fine.

 

I was thinking the big starter gear was somehow getting behind the small gear and binding on the crankshaft housing. I admit that is a big assumption.

 

Took the motor to a Honda mechanic today and he had not heard of a problem like mine. Showed his the slop in the big starter gear and wear on the housing and he said if it was his he would add a shim. Went to Tractor Supply and found a washer that would work perfectly. I was going to post this information and reread budedm's reply. This shim cannot solve my problem because the recoil starter rotates the shaft in the free direction of the one way clutch. The big starter gear does not move when using the recoil starter. Now I am back to square one.

My neighbor suggested it might be a broken ring. The motor has always started easily and runs great. What would only bind sometimes and when it does be bind be strong enough to break the recoil starter rope?

 

I gave up and took the motor to a mechanic. He checked everything and could not find a problem. Had him install new rings, exhaust valve and put the motor back together. So far I have not had any starting problems. Could a bad exhaust valve be the problem?