D2 starting pinion

Hi All, Have been wading thru the old posts to try to shed more light on my D2-5U starting problem. The clutch doesnt go in with a "snap" as it should and I have had a feww D2s. This is the first one that I have encountered like it. And so it throws out early and I end up having to "hold"/force the small engagement lever while holding the clutch in. Not good. It almost seems like the starting clutch is too tight and has not enough play to snap in place (?). Am very reluctant to lift the Pony with all its work just to get the starter pinion out only to find that maybe it can be fixed with adjustment ! I know all you highly skilled and learned Cat comrades must have an answer or be able to help 😊 Thanks and Happy Easter. OzCat

If the pinion clutch lever feels too tight to snap I would remove the square cover on top of the pinion clutch housing and back the adjusting collar off enough to get a good snap when the clutch engages. Then, if the pinion gear is disengaging from the ring gear too early you can remove the small round cover just under the front of the floor board and tighten the pinion latches. Remove the cotter pins and tighten the screws one half turn, then put the cotter pins back and test it. If the pinion still kicks out early do another half turn on each and test again. You don't want to get the pinion adjustment too tight or you could over speed the pony.

Thanks friend. I did back it off a little and will go one more and see how that is. Then if that fails, I will go for the latches and do them. Thanks very much for your input. Regards, OzCat