I found my problem. I took the starter off this afternoon and took it apart. I would have never guessed it in a million years, but one of the countersunk screws that hold one of the four field coil poles on had come out and the pole piece wedged around the armature and almost locked it up. Ive been messing around with starters and generators all my life and never seen one of these bolts come out. I found the screw in the bilge and put it back in, using Locktight on the threads and tightened the crap out of it! I cleaned it all up, greased the bearings and put it back together. I bench tested it and it seems ok, sounds a little tight but it runs ok. I'm a little leary of it now. I guess I'll give it a try the next day I have off.
