A permanently engaged starter assembly includes a ring gear, a return gear, and a starter gear. The return gear is fixed to a shaft of a starter return mechanism. The starter gear is arranged for fixing to a shaft of a starter motor and arranged in a torque path between the ring gear and the return gear. In an example embodiment, the ring gear has a central axis and the return gear is radially outside of the starter gear when measured from the ring gear central axis. In an example embodiment, the ring gear includes a first gear tooth, the return gear includes a second gear tooth, and the starter gear includes third and fourth gear teeth engaged with the first and second gear teeth, respectively.

A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.

An engine start system which may be employed in automotive idle stop systems. To start an engine, the system brings a pinion gear into engagement with a ring gear coupled to the engine and turns on an electric motor to rotate the ring gear through the pinion gear to crank the engine. When it is requested to start the engine during deceleration of the engine before stop thereof, the system thrusts the pinion into engagement with the ring gear and then turns on the motor to rotate the pinion gear, in other words, delays the activation of the motor until after the pinion gear has engaged the ring gear. This minimizes mechanical impact or noise arising from the engagement of the pinion gear with the ring gear and improves the reliability in engagement with the ring gear during the deceleration of the engine and durability of the system.

A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.