Count teeth on pinion. Count teeth on fly wheel. Turn flywheel exactly 90 degrees as you count and multiply by four. Report numbers. Don't guess.
Grinding noise can be not engaging at all, weak engagement or clutch slip, broken/worn teeth, foot levers/pivot points worn, not enough throw with unknown starter parts, starter growling, etc etc. Start with making sure pinion and flywheel gears are matched correctly.
I know it's hard to beat logic of it was working for so long and now it doesn't, but sometimes you have to forget that and start over. Especially when odd modified parts are discovered and parts were taken apart and possibly miss assembled.....or as things wear out.
Keep this previous comment in the back of your mind "There is a phenolic thrust washer on the commutator end that could be worn or missing. Maybe that could cause movement.".......or could cause weak engagement.
Very difficult to find the problem from our house. You need to be studying the situation carefully using us as a guide.
Last edited by bartamos; 09/05/2023 9:38 PM.
