Starter bench test...problem solved (1 Viewer)

[Kernal]

I forget if you mentioned it, originally did you pull the starter down to the armature and brushes?

 

[Malleus]

Many thanks to everyone who kibbitzed on this exercise. The problem was, in fact, an open circuit between the solenoid power leas and the starter motor power lead. The kind folks who packed the rebuild kit included a spacer ring that fit neatly between the solenoid contacts. I neglected to check the thickness of the ring, which just happens to be in excess of the thickness of the contacts, insulating the plunger form both contacts. Once I removed the ring, the motor and solenoid worked flawlessly.

Two takeaways: a) don't put in parts you didn't take out ; b) 18 guage wire is too small for the primary power lead to the starter. It'll work for the ground and ignition contacts, but you need a minimum 6-guage (the OEM harness has 4 16-gauge) wire to prevent a finger singeing
...as rebuilt with the (not needed) spacer:

...as rebuilt-ed so that it works:

Notice the socket head cap screws I replaced the OEM (Denso) JIS silly putty screws with - no more stripped screws! I did the same on the brush cap end, too.

 

[Malleus]

I forget if you mentioned it, originally did you pull the starter down to the armature and brushes?

Yes, I intended to remove all the replaceable parts, just as a PM measure, but I left the OEM brushes in place because, a) they're crimped onto the field coil in such a way that I think you'd have to replaced the coil if you removed them, and b) they still had half the OEM thickness left.

FWIW, this was a "while I was in there" PM while the head was out, 'cause it's way easier to get to starter bolt when the intake's out.