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Interesting. I have had the grinding issue as well but just replaced the starter with a new one last week (reduction type). I noticed the shaft the starter pinion moves on also moves about a quarter inch which could be the culprit. Seems to be quite sloppy in there so I am thinking a spacer or washer has come apart and is causing the play in the shaft. My original starter lasted 900 hours, replacement about 150 before the grinding started, so some day I will open it up to see if I can rescue it for a spare.
Paul
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So far my pinion modification is still working…… but if the disengagement happens again I will chuck the snout of the starter housing in my Bridgeport and mill 1/16″ off the mounting face to bring it closer to the flywheel.For easier mounting I am thinking I could drop the starter snout into a square mold and pour concrete around it.That square block of concrete holding the starter snout would be much easier to mount in my milling vise.
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