Having issues with a starter motor.... most of the time when I try to start it, the starter motor just spins freely without engaging with the ring gear. After a few tries it usually ends up engaging and working fine.

 

It doesn't usually crunch gears when it is spinning freely, so mustn't be getting pushed on to the ring gear at all.

 

I've had the thing apart - it all looks fine, and the pinion seems to slide out nice and smoothly..... Only thing I noticed was about 3-4mm of end play on the motor shaft - not sure if this is normal or not.....

 

Any ideas on what the problem may be?

 

(Its a direct drive one, not a gear reduction one...)

sounds like a solenoid issue. Make sure the solenoid can move freely back and forth. (solenoid might be called a bendix.. its the switch thingy on the side of the starter motor, that pushes the shaft forward to engage the flywheel gear)

Yes i had it all apart - the solenoid itself must be working since the starter motor itself gets power - this can only happen once the solenoid has operated.....

Seems like it would be a problem with the linkage between the solenoid and pinion slider, but it looks ok....

the solonoid can also be getting weak (Magnetically) and not have enough force to fully push the plunger , pushing or engaging the sprocket towards the flywheel

the solonoid can also be getting weak (Magnetically) and not have enough force to fully push the plunger , pushing or engaging the sprocket towards the flywheel

 

See my post below - the solenoid is engaging properly, since the starter motor itself gets power.