Is it possible for a starter pinion to not fully reteact? I think my flywheel keeps hitting my starter pinion. It doesn't always happen, just sometimes.

i had problems with a remanufactured replacement starter once that i bought from a local parts supplier.when i turned the key the bendix shot out and jammed itself in the flywheel and stayed there.it cooked my battery in the process;i guess because the circuit stayed open.i had studied everything thoroughly before installation and had the proper number of shims and all.i removed the starter and took it back.the man put the starter on their little machine and it spun and acted perfectly.i explained to him that something was just not right.he put it on the counter and i turned it over and examined the mounting surface.it was then i noticed the area around the starter bolt holes on the block mating surf graemlins/sad.gif graemlins/sad.gif ace of the starter was scarred due to what was probably a chipped tool bit wherever the thing was made/remanufactured.it was just enough to throw the alignment of the bendix/flywheel teeth off.

you might want to remove the starter and check for any foreign object or trash on or between it and the block mounting surface.also,you could have a shim shifting if you have them stacked.it doesn't take much to throw the pinion/flywheel alignment off enough to cause the pinion to engage at an angle and try to stick open.the only other thing i know of is the pinion mechanism could be messed up.

are your flywheel bolts tight? ;)