The life a starter is not counted in miles but starts.The starter is the original one and was wore out it had over250,000 miles on it.
No, as long as the starter output splines mesh with the drive sprocket and the mount bolts line up that is not the problem.Can I have the starter in to far ,before I tighten the bolts I pushed the starter in as far as it would go. It does have a little play to it.
The starter is splined to the drive gear in the engine. It's connected to the driven gear by a chain. The starter does not contact the starter clutch assy.The only thing that starter touches is the starter clutch.
With the amount of miles on the bike, I would be willing to say the chain the starter turns to start the motor,has alot of slack in it and is hitting the sides of the case. If the original gear was used, it might have worn down to the point its allowing more slack in the chain. Chains stretch, but when the motor speeds up, the chain tightens so its not noticeable.,,
I never said it did. Vibration from the motor can cause the chain to tighten up and loosen up. Like how you can hear a sound at some rpms, but nothing at others.,,The starter chain does not turn when the engine is running