Thanks for the ideas. Here's some more info. The counters are pretty simple to remove. There's 2 small screws that are just "friction screws" that hold/set the counters on the actual molded posts that the counter is attached too. I may of buggered up the counter, but probably not.

Bigdog is correct. The cable size and amount would definately make a difference. I just mic'd the old cable and compared it to the new stuff and it's the same. Before I submitted my post I had checked for the 4 plastic posts that index the counter and they were also intact.

I guess I'll change the counters from one 'rigger to the other and see if the problem persists. Does anyone know how much cable comes on a stock Scotty. I'll try to look it up too. After I had re-spooled the 'rigger I quickly compared (visually) the amount of wire on the spools and it wasn't obviuos which one I had just re-spooled even.