Question 1: I can't tell if the starter drive bendix is bad or not. It seems to operate fine, but the piece on the opposite end of the gear end doesn't look like the new one in this photo. Is mine ok or not?

The old one appears to be missing the spring that pushes the pinion gear away from the flywheel - put in a new one.

Question 2: Also, appears to be a broken bushing on the motor side where the bendix goes...anyone have a part number and how-to to replace that?

Bushing part # 3083669 - 1ea in crankcase and recoil cover

Question 3: I'm finding little pieces of what appeared to be a spring at one point...was that something that belonged to the pull start or would that have come from someplace else?

The spring could be the recoil pawl retraction spring or the Bendix spring or both.

Question 4: What would be the best way to clean out all the shavings in my housings....ideally without taking the flywheel off?

You need to take the flywheel off to remove steel shrapnel from the magnets and ti inspect the flywheel and stator for damage. It would behoove you to remove the stator to expedite and make cleaning more thorough. It may have been a dislodged magnet that was the cause of the failure. Clean things with compressed air and spray contact or brake cleaner. Wash it down with the solvent and blow it dry with compressed air which in addition to drying, may dislodge small hidden metal bits hiding in obscure places

 

What's the best way to remove the old bushing? The bushing in the destroyed pull start housing still looks good, could i extract that one somehow and reuse it on the other side since i'll be scrapping that cover?

I need to get a new pull start housing and pull start assembly. That last one was a $50 unit off of EBAY. Is there a more reputable one i can buy that won't explode again?!

 

The best way to remove the bushing is to run a thread tap into it, destroying the bushing in preparation of installation of a new bushing - since the cover is destroyed, hacksaw through the casting and split it to extract the bushing - the broken bushing can be tapped with threads and a short piece of plastic or steel pipe with a bolt and washer can be fashioned into a puller.

 

@latebird any suggestions for who/where to get new pull start housing assembly?

 

Not really - they were discontinued about 1998 - NICHE has them on EBAY for $40 with free shipping - other than that is a used one needing to be serviced and the rope replaced for $35

 

Just bought a Niche brand one on Ebay like you mentioned. This one looks like the pull start handle is angled out, so hopefully this time the handle won't be melted to the exhaust.

 

Just make sure the handle is seated on it's nipple to keep water out - water won'r affect the ignition, but it's hard on starter parts - anytime it's run through deep water or a couple times a year whether it's run through deep water or not, it needs to have the drain plug removed just to drain any accumulated condensation or errant water intrusion from the cavity.