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Mumble’s advice is spot on, and it sounds like you have it assembled correctly. It is so important that the helix and gear groove where the friction spring rides is super clean and dry. You mentioned that you removed the friction spring and “tightened it up a bit”….This should have done the trick if everything else is OK. Did the friction spring look worn? The next time you pull the gear off, try spinning the friction spring on the gear to see how easy/hard it is to move on the gear…Needless to say, it should not move freely in the gear groove. I would not try to rough up the gear groove, that will probably just ruin it….I suppose it is possible that the gear groove is excessively worn, it is only plastic, but I have never seen that condition…
Again, try spinning the friction spring in the gear groove once it is off the starter….If it seems loose, then the spring is worn/loose, or perhaps the groove in the gear is worn…You mentioned these engines were used commercially, so anything is possible…