any more ideas?

 

are you sure you got the right bendix and it is engaging with the starter/flywheel.
just a thought but theres not really anything i can think of mechanically that could go wrong with a new bendix.

 

Ya it meshes great with starter, but it wont mesh in the flywheel when trying to start. It is the right gear though

 

when your holding the bendix does it freely spin one way and easily pushes out when you twist it the other way?

 

When you had the starter apart, did you clean (lightly sand) the brushes and the surface the brushes ride on? If they're glazed over they won't make a good connection and the starter won't spin as fast as it should.

 

mk has a point marmon the brushes+ the commutator (the brushes contact this at end of starter) should be lightly sanded with 200 or more grit carefully+remove any sand,+shine the commutator just alittle by wrapping the paper around and turning.i've woke up many starters this way, the carbon tracking(blackness)does not conduct electricity well+has high resistance(slow turn).

 

Ya I polished them up with steel wool.(thats all i had) Maybe I'll try again with some emory cloth? Anybody know what voltage to look for or how to test the starter circuit for resistance?

 

if everything is shinny you don't have to repeat.....does your engine pull start easily?

 

pull starts just fine, except when it rips the cord out of your hand, thats why i hate using it.

 

well i think i fixed it. I ground a bigger lead on the gear with a zip cut and its worked 10 out of 10 times so far. Hopefully i didnt take the hardness out of the gear and it keeps working. Thanks for the help everyone