Bike I am reassembling at the moment has a sluggish starter. Its always been the case for the past 5 years or so since I purchased it.It always starts, but as you push the button, its almost like the battery is flat as nothing happens and then it cranks over and fires. Its not the battery as I have tried several other known good batteries, with the same result, its more like the starter isn't getting the juice. Any ideas or known issues? thanks.

It could be a sluggish starter soliniod mine was playing up recently and it was a corroded connection which when cleaned cured the problem. You can also upgrade the large supply cables to the starter as they are undersized and have difficulty delivering the power to the starter!

Mine was always sluggish too. I took it off, cleaned the commutator and replaced the brushes. It made no difference. A few months later the brushes stuck. I had to remove the starter again to free the brushes and make sure they were moving freely. The next year it did it again
This time the brush on the earthing side had more or less welded itself to the brush holder. So bugger it. I went out and bought a new starter from Electrex. With it fitted the bike has never turned over so quickly, seems like twice as quick.
I came to the conclusion that the original starter must have an internal short in the armature windings causing it to draw too much current and reduce its power.

Good news story, I pulled the positive wire from the battery to the solenoid and the one from the solenoid to the starter. The connections didn't look obviously bad, just a little scaly. Got stuck into them while I was there with a file and wire brush anyway, not expecting anything much to have changed. WooHoo, she cranks like mad thing now, never started like this ever, just touch the button and she is away. Happy days.

Good news. It pays to check all the connections first.

The wonders of the internet, how people in the Uk can help bikers on the other side of the world. Always glad to help a fellow motorcyclist!

I recommend updating your wires. I installed this kit and man what a difference. Bikes kicks off twice as quick as it use to. Saves on the sprag starter clutch and the battery.

https://motolectric.com/