Norm depending on the size of the drill you used, the recoil assembly itself maybe the problem. I have seen where the starter pulley would bind on the center post due to wear on cheaper recoils here and I have replace several over the years. As for the tooth wear it is normal for them to wear out and isn't cause by the compression load though most of these 42CC class saw run 130-165 psi compression when new. Sometimes the wear is from sticky engagement pawls.
And yes the customers are bad to not tell us about problems hoping we will fix them for free.
It sorta like the Bobcat UTV I just sent out of the shop. It came in with front end bushing and CV boots bad. Engine was barely able to run. The customer said he had checked by the Bobcat dealer and was it was a bad fuel pump. THe frond end repairs was no problem other the few hours it took cutting out the bolts. The fuel pump was rebuilt but it only made the problem worse. The ECM was saying that the TPS was bad so I replaced it, still no change. Found the injector partially clogged so I installed a new one, still no change. By accident I found that the system wasn't charging. What I found as a cause was the stator wires were complete worn though and shorting along the CPS sensor wire rubbed bare. I repaired the damages and believe it or not the problem was corrected. I am thinking the bare CPS wires was causing the problem.
Anyway I now got to buy a new crimper so I can do weathertite and Metripack terminals. Always something isn't it?
