Bushing on starter. Occasionally has trouble starting, but always starts within 4 tries. Would cost $1200 to fix, not worth fixing. Will just continue to drive and put up with occasional starting problem.
Other than the problem with the starter, this has been a great car. It takes a bit to get up to speed on the highway, but once it gets up there it drives like a charm, have to watch the speed. Great little car!!
According to Bosch parts company, replacing the starter drive with improved bevel of the teeth will cure grinding noise during start. Such improved drive do not have flange at the pinion gear. See my review "Good toy for do it yourself...", posted January, 06.$1200 seems unreasonably high. Good luck.