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Definitely not hitting the coil. It hits the plate before it gets to the coil. Its like the flywheel is sitting down about a 1/16-1/8th inch low. I was thinking about filing a taper on the plate, but figured that is addressing the symptom and not the issue. I will take a picture when I have my hands on it again. It might be dragging on one side, but it hits a hard stop when it hits the spot on the plate. Right now the powerhead is off and in a box while we are waiting for parts, and the girlfriend has everything else in pieces cleaning it for reassembly.
Rings under the plate – I will need to look at them. I removed them after the issue started, but everything seemed good. The armature plate fits well – everything is nice and tight. Motor was in really good shape, just no spark.
I will check the flywheel again for how the keyway looks on it. I am thinking it might not be bent as we didn’t have clearance issues initially, but only after "popping the top" a bunch of times in our odyssey to find spark. Before you ask – i did use a puller that had bolts going into the flywheel and not arms on the outside.
Pretty sure we swapped points from the working to the non-working side with no result.
That is why this is such a mystery. Changing things around should have got us spark. Then suddenly having clearance issues really melted my mind.