Finally got to start taking it all back apart, When i had it open the first thing i noticed was the "clutch/Starter gear" behind the rotor would not turn either direction by hand, the other gears and washers all appear to be in good shape.
When i pulled the rotor, the obvious thing is damage to the woodruff key(see the picture). When i initially pulled it(before doohickey), it was very loose and fell out, during reassembly it was a challenge to keep in place but seemed to go together fine.....
The rotor came off just fine, the 'clutch' will not slide off over the key, and for the life of me i cannot get the key out.
Any insight. ideas, or general hazing gladly accepted.
If the gear reduction sets were still in-place, the ring gear can NOT be Turned either direction by hand. DO NOT attempt to use the starter motor with the outer ends of the reduction gears Un-Supported.
The starter motor holds the ring gear stationary, unless the starter motor is doing the turning!
Where is the spacer washer that is supposed to be between the ring gear & the rotor? Isn't it the same diameter as the ring gear bushing?
Did each pair of reduction gears have ONLY ONE Shim on each side?
Use a pin punch & hammer to tap Straight Down on the back end of the woodruff key to 'roll it Up' in its key way. Or use pair of side-cutters / wire-nippers to grip the woodruff key.
If the woodruff key is perfectly level the spacer washer & ring gear bushing may pass over it.
If we use an awl or center punch to place two stipples/dimples on one side of the lower half of the woodruff key to make it stay in-place during assembly, we will need to use tools to extract it.
Is that woodruff key sheared? Not a good view of it!