Just a quick update. I reassembled the starter using two thick and one thin washer (#9 in diagram above). I just couldn't find another thin washer. I also added a little graphite powder to the tip of the commutator (where it says "ground here?" in the diagram above).
So far so good. I fired it up about 10 times before mounting on the bike and haven't had any problems since I put everything back together. No squealing noise, and it spins right up every time.
Fingers crossed that it stays that way.
Permanent and perpetual noob.
1979 KZ750 Twin
2009 Kawasaki Versys
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