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The pinion gear should be completely clear of the ring gear when the electric starter is disengaged.
Be careful pushing/pulling that pinion gear - you could inadvertently engage the starter. If you haven't done so, it's a good idea to isolate the battery before working on the starter.
yep, all disconnected, thanks.
Went to local battery/starter shop. They didn't have the rebuild parts in stock, so got them ordered. The curved washer that sits under plunger, had gotten twisted a bit, which caused it to come up alongside the plunger, and that is what was holding the starter gear engaged to flywheel.
I must have over tightened the battery cable to starter and spun the piece inside. ? Weird, that it was still starting because that had been 3 or 4 weeks ago.
Also found the crimp on fitting at battery (positive cable) was loose enough to be pulled off easily.
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