AND THE SUSPECT IS..<DRUM ROLL>
The
CHEAP CHINESE STARTER GEAR.
My dad helped me today, we tried lubing and cleaning, never worked, cleaned all the relay connections etc.
then we installed the starter, hooked everything up. BUT left the starter un bolted, and sitting ontop of the engine (ran a alligator clip from the solenoid bolt to ground), it spun up every time, closer inspection the so called "steel" gear has kind of mushroomed on the end of the teeth. the flywheel teeth are good.
so i guess the gear was hanging on the flywheel enough to not let the solenoid retract all the way and that's why tapping the starter, NOT the solenoid would work.
i'm debating either filing them a bit, OR, i can purchase the OEM Kawasaki gear on ebay for 25 bucks. that gear should fit this starter as the starter is a copy of the original. that's what i'm hoping.