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> Turned out to be the gear on the starter bendix. 

About 99 44/100 % of the problems with Continental pull type starters can
be 
traced to incorrectly adjusted starter switches.  It is critical that the 
starter gear be fully engaged before power is applied to the motor.  To 
paraphrase one of Continental's service bulletins "it is impossible to
damage 
a correctly adjusted starter drive."

John

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