Hi, Thanks for quick reply. I had this same thing happen before with HS50 that was newly rebuilt like this engine and key was sheared because of not torquing FW correctly. Don't think I had spark with that HS50. This HS40 I used a torque wrench to spec. Both would start 1st or 2nd pull and running good for about a week while testing & fine tuning carb then one day won't start even with starting fluid.
What sucks is engine is already painted and mounted on the bike and why asking before taking housing off to see.