My 1990 F-L was suffering from a worn-out starter clutch. Hard to start when cold, impossible to start when hot, then finally impossible to start at all. Thanks especially to sebastionbear as well as others whose hints I took on board, she might be back on the road soon.

I fitted a washer, filed down to about 0.5mm, behind the starter clutch springs. It took me three weeks to find how to slacken off the alternator chain (with a wire coat-hanger) before I could get the starter clutch back in! Tonight I connected the battery and after a second or two for fuel to get to the carbs, she fired up! After she warmed up, I cut the engine, and she fired up again immediately! Tomorrow I might get time to put the fairing back on and go for a little ride, then hopefully back to commuting again.

If I didn't have a long attack of gout, a nagging wife and loads of DIY and decorating to do, I think I could have done it over a couple of days. But for me it was a five-week job. I might have to do it again if the washer fix doesn't last.

On the way, I found:
- the carburetor boot clamps were all loose
- the two halves of the alternator connector had melted and fused together (now five pairs of bullet connectors)
- it's much easier to attach the throttle cables with the carbs out
- the fuel overflow funnel was all cracked (now has silicon sealant to hold it together)
- best way (for me) to attach carbs was first to attach at the airbox, then use a hammer and softish piece of wood to gently work into the engine side

 

Good stuff. With the fused connector - check your R/R - it may be what caused that melting of the plug in the first place

 

glad your back up and running

 

Thanks Sprock.
Replaced the R/R a few months ago - hopefully the connector melted before then.
Commuted into London this morning. Hopefully she'll start up tonight and I'll check for leaks when I get home.

 

Well done mate, one job I've not had to do yet.

But then she's got about 53,000 miles on her now, so might not be too far down the road.

 

Mine finally gave up the ghost (refused to start at all) at 54,445 miles...

Started up fine this evening, ran nicely (apart from camchain rattle), got home, a bit worried that smell of petrol is stronger than usual. Will check it out this weekend.

 

Well that's a + , now she's getting you back home at least

Wonder if the fuel bowl gaskets are weeping ? first place I'd look with her running

 

Good job. I have not had to do that job yet. LOL My last bike a 88 Hurricane 1000 gave me other problems (easy fixes) but never that issue, I sold her with 62K... Hopefully the 94 I have now will be a good girl. LOL

 

Aaaaargh, when will it all stop?

Are these gaskets visible without removing the carbs? Can I do a bodge fix, e.g. with silicon sealant or instant gasket without disassembling?

Just a thought!

 

same happened to me on my 88, rebuilt and running 2 days later leaking petrol, if you need new gaskets follow this link
Search
i pulled mine off and replaced the needles and seats, not sure if your going to be able to seal them in situ though