Life has a way of interrupting my projects for sure. What appeared to work initially again failed. Pinion Gear won't raise when pulling the start rope. I again dis-assembled the starter and methodically approached this project again with a "fresh Look" and believe I now have the final solution. It appeared after careful examination, that the cross hole in the top of the shaft (where the pin goes through to raise the pinion gear) had "flared" out just a small amount on each side. I was only measuring a few thousandths of deformation, but it was enough to keep the pinion gear from moving freely. I carefully filed the top of the shaft round again, then stoned it to remove any filing marks, then went to the lathe to polish the shaft. At most I only removed a couple of 10'ths from the diameter but was able to remove ALL swelling at the cross hole location. The starter now works smoothly each and every time with no issues whatsoever. Problem finally solved.
