Follow up from my original post (below):

I've replaced the starter bushing this morning (using a 12mm tap, for
future reference), but I'm still having problems. About 2 times out of
three, once the key is turned, it sounds like the starter motor is
spinning quickly, but the engine doesn't turn over. If I keep the key
turned, it sounds like the starter motor starts to slow down gradually,
and after a couple seconds engages the flywheel. About 1 time out of
three it starts right up.

I've checked all the wiring and it seems all right. It shows the same
symptoms if I short the two terminals on the starter, and I even ran an
extra jumper cable from the house battery to the solenoid terminal.

I don't think it is broken flywheel teeth, I checked.

I've tried it bypassing the ignition switch, same thing.

Don't really have any ideas on how to proceed, any suggestions?

Thanks,
 Jeff Kennedy

> On 29-May-05, at 6:23 PM, Jeff Kennedy wrote:
>
>> Hi all,
>>  For the past couple of years my starter has worked only about every
>> other time. Sometimes it works great first turn, other times it
>> sounds like it is spinning but not extended (engaging the flywheel),
>> or maybe the gear is extending and not spinning? The sound is a
>> steady loud hum, but if you keep the key turned it gets real loud,
>> almost like a "honk",
>> for a bout a second. Sometimes it does every time you turn the key,
>> and
>> its getting worse.
>>
>> I installed a rebuilt starter this week, thinking that was the
>> problem. It worked great for about the first ten starts yet now its
>> doing the exact same thing. So I guess that means I'll be replacing
>> the wiring, unless anyone has wisdom that suggests otherwise
>>
>> Thanks,
>> Jeff Kennedy
>> '84 Westy with a Tiico