96.xp can't get starter back on

[davekessler]

Had engine rebuilt by ses. Original flywheel on. OEM starter. Can't seem to get it back on. Comes to with 1/8" then binding at the top. Can draw it closer with screw but bottom starts to close, top stay open which skews the starter. I don't want to force it. My understanding is that the teeth only mesh up once it's engaged. Seems like it's hitting the flywheel. Tried to move the flywheel to help it mesh up but won't go. Now have flywheel cover off. Still can't figure it out. Engine is out on bench. Any suggestions? Could ses have missed a spacer when reinstalling the flywheel? Total newbie so any help or suggestions are appreciated.

 

[Matt Braley]

Loosen the ground wire up and rotate it a little. Re-tighten and your golden(unless you need to repeat this step again).

 

[davekessler]

I don't have the ground wire attached as the motor is on my bench right now. I did take the starter support bracket off the back to see if that would help. One thing to mention is that I did replace the brushes and seals on the starter so I had it apart. I marked the top and bottom of the casing to make sure it went back together again the same way. Maybe I don't have the starter together correctly?

 

[Matt Braley]

I guess not. Once you wrestle it in there within an inch the work is usually done.

 

[davekessler]

Do you know if the brush holder inside has to be oriented a particular way? Ill check the marks again just to make sure I have it assembled correctly.

 

[wfo speedracer]

Teeth only mesh up when the starter clutch spins up

 

[davekessler]

Took the starter apart, checked the orientation of the brush holder and it was all in correctly. Still cant get the thing in. Not sure what to do next. It is definitely the outer ring of the starter that wont slide into the the receiving hole on the backside of the flywheel housing. I am stumped.

 

[davekessler]

Here's a couple pics. Anything look unusual?

 

[davekessler]

Here is what happens when I tighten it. It pinches on one side the bottom and opens on the top.

 

[Matt Braley]

It's an odd case. That normally does not happen. Perhaps there is a burr in the mag cover. Or maybe the short 6mm bolt that holds the back of the starter is screwed in the case underneath.

 

[mikidymac]

You can clearly see that the starter can with the magnets is not seated correctly on the starter end. You can even see the o-ring peaking out. Your starter is not assembled correctly.

 

[davekessler]

Unfortunately That's because when i took that picture I had loosened the bolts in the back to see if there was something in the assembley that was causing the teeth and or bendix to protrude farther forward. So my thought was if I loosened up the rear screws and it went in OK then I would know that something wasn't assembled right. I have triple checked the assembley of the starter and I am pretty sure its correct. Should have mentioned that in the picture.

 

[davekessler]

Had to file down the casting joint. There was a ridge in the joint in the flywheel casting at the top side of the hole the starter fits into. Then it went in.