I apologize for falling off the face of the earth, but yes I do push the key to activate the primer. I know the primer is working because when I prime the ball you can see the fuel fill the filter assembly, then when the primer is activated the fuel flows out.
I don't know if I explained the "solution" well enough so I'll try again. I've noticed that this is actually much more of a cold start issue, either cold or sitting for 20+ minutes or so. If the engine does not fire I pull the cover and turn the primer manually until I hear it click (sometimes it takes 1/2 sec, sometimes it takes a few seconds), return it to closed, and turn the key. Usually fires right up. So
1) What is the click?
2) If turning the primer manually is doing the same thing as the pushing the key then why won't it turn over unless I get the "click"?