I recently ask if anybody knew where I could find a rebuilt starter due to my starter dragging and did eventually find a kit which I bought and rebuilt and proceded to rebuild my starter. After doing this, I have to admit that it worked a little better but not nearly as good as it should, I tried to start my bike today and it would hardly turn over and it's over seventy degrees outside.
Before I ordered the rebuild kit, I checked all the connections, (battery, solonoid, starter, ect) and they were tight, not to mention very clean. I also took my battery to Autozone who said it's performing even better than rated so I've pretty much ruled out connections and battery already. Today I tried jumping strait to the starter with the battery using battery cables with the battery ground to the frame and the positive lead going from battery to starter.
It is worth mentioning that I rebuilt the starter, jumped it from my lawnmower to loosen up the bushings a bit and it spun like a top but when I put it on the bike, it spun a few time and locked up. I took it back off and had to tap it in order to get the shaft loose from one of the bushings (replacement kit had bushing rather than roller bearing) and when I did, I noticed that something had cut a small groove in the shaft. I have no idea what could have caused that unless it was a little chip off the lock ring that I noticed has broken off which was very small. I had to pry the ring off with a screwdriver as not one of my ring pliars were small enough.
Anyway, I guess I'm going to have to bite the bullet and buy a new starter. I read somewhere that I should replace it with a virago starter as it has thiry percent more power but I'm not sure which one, either by cc or year model. I figured that somebody here would know which one or if theres something else that I should check first. Any info would be very much appreiciated.

Thanks

It could be you did something wrong on the rebuild. Or there is something wrong with the starter that the rebuild didn't cover. Or there is something binding in the starter gears or clutch and it won't let the starter turn the motor over. If you want a stronger starter get a Warrior starter. But I would be double triple sure it's the starter before I bought one.

Just a word of caution. If Autozone checked the battery make sure they did it right. Reason I say this is I used to be a manager at Advance Auto Parts(back when I stayed poor) LMFAO The testers that they use are primarily designed for car batteries and perform horribly on atv and motorcycle batteries. The machine actually frys about 1 in 10 of em trying to test them too hard. I myself have tested harley batteries and gotten good results only to have that battery truly be bad. Customers reported back that they purchased a new battery and that was the end of the problem. At advance you can probably get one and you could even get a gel type like the Harleys have for under 90 bucks. Just something to think about. Also, you might want to take the starter to Advance and have it bench tested. They'll do it for free. Either way, good luck and I hope ya quit havin problems soon.

Hi

That sounds like good advice from both of you. As far as the rebuild, I can tell you without a doubt that it doesn't spin as well as it did before the groove got cut in the shaft. I sanded with 400 and then with 600, but when I turn the gear by hand, it has catches or tight spots whereas before, it was tight, without catches,,,smooth if a little tight, which I take is good.
As to the battery, we don't have an Advanced Auto Parts store here in town, only Greenlight Auto, Autozone, and Crow Burlingame. There is nothing that I would like more right now is to be able to independently check the starter because I have a lot less confidence on my rebuild since the shaft got a groove cut in it.
As for the battery, I tend to think it's ok because the starter was still dragging after complety bypassing the battery, and connections with the jumper cables. I jumped from my lawn mower battey which is about the size of a car battery and less than a year old strait to the starter with the ground going from the lawn mower battery to the frame near the starter. I might mention that the battery in my bike is less than a year old. it was purchased around Apr, or May.
It's worth mentioning that my starter trouble gradually got worse after my solonoid went out. When it did, the starter kept spinning until it stopped before I could get the seat off and the battery disconnected. I later took the solonoid off, cleaned it off, tapped around on it and replaced it only to find that it worked for a couple of days and the same thing happened again. I then replaced it and as near as I can remember thats about the time my starter started its downhill roll. It's slowly gotten worse since them or this past July which may be all more reason to suspect the starter. What do you guys think?

You might want to double check everything with the solenoid too then.

I forgot to ask. Do you know which Warrior year model will fit a 1999 bike.

90% sure any year will work. One thing I forgot to mention is you might need to get a new starter relay (you have a 99 right?) if you go with the Warrior starter. You could try and find a used one for a 1700 or get one from the dealer. They only make the stronger one now so you can't get the wrong one.

Thanks for the up's Musky, I think that's what I'll do.