Right on..thanks for the response guys! [color=#011a4d]DeepPurplishBlue[/color]
had it right. i started taking things apart before i had heard back from anyone and it was the starter clutch. the nasty noises I was hearing while runnin the e-start was the starter clutch slipping. The noise came while the clutch was free spinning and slamming as it engaged. it was slowing coming apart with each start. For you other newbies checking this thread out, I'll break it down for you to better understand what this newbie didnt. The free spinning starter I thought i was hearing was actually a well oiled machine, cause what I was hearing was the starter, the ider gear and the starter clutch gear all spinning at once since the starter clutch was not engaging.(it didnt sound like that much was moving!). While in there i did replace the woodruff key . it was pretty worn given its stationary job and was probably pretty stressed due to not having the starter mod for so many years. better safe than sorry. All n all a pretty easy fix and the parts weren't too spendy. One thing. Like I mentioned I also just completed the starter mod using the 04 damperner assembly, (thanks [color=#011a4d]Rocky739[/color]
for the parts break down in the '03 WR450 Starter Conversion Tutorial) but I am a little concerned about how loose fitting the washers are at each side of the damper
assembly (the following fiche
link is to RonAyers.com. ,a good source for lesser expensive parts, http://www.ronayers..../STARTER_CLUTCH
i understand that these washers are only going to be sliding around when the starter is being used... but given the tight tolerances of the rest of the bike..seems odd these would be this loose. Its not that they are the wrong diameter for the shaft, but there are grooves in the shaft right where the washers sit, making the fit sloppy.(?) any thoughts? Thanks. ill check back Monday as i am out to the Nevada desert and into some SWEET sand washes! Cheers Brothers and thanks TT for all the very helpful info!!!