Did you replace the battery? Mine would spin up without engaging. Worked right only 50%. A Lithium Ion battery will "throw" the bendix out much faster so it engages right away. I put some synthetic engine oil on the bendix and light wipe of grease on the ring gear. I even did some gear tooth profiling on the bendix gear, but it didn't help. The Yuasa battery is weak.
Perhaps some of the return springs are too strong. Was there any change in the part numbers for these units?
Jump your bike battery from a car or truck. If the bendix engages every time, you know it's a battery issue.
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2011 EC250E
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