‘94 vfr won’t start after starter clutch replacement

Discussion in 'Mechanics Garage' started by Jim DeFina, Aug 16, 2021.

  1. Jim DeFina

    Jim DeFina New Member

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    Hey y’all.
    Just went through the starter clutch rebuild (and oil change). Put her all back together and the motor turns over great. But won’t actually start, like not even a sputter. I check my spark and I’m good on 3 cylinders. #1 has zero spark. I’ve check with my meter the coil, the coil wire, changed the plug. I checked resistance on the pulse generator pins.
    All these tested good!
    My thinking is that when I changed the starter clutch I did have to remove the PG. but I reinstalled it just as it was and there’s no adjustment to those….?
    Also, why would a motor not even sputter / start if I have spark in 3 cylinders.
    I’m out of options, please HELP !

    Thx
    Jim


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    Last edited: Aug 16, 2021
  2. ridervfr

    ridervfr Member

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    Weird, I did not have to remove the pulse generator when I did mine, you have something backwards on the gears or something, take of the cover and re-think what you did. If the bike fired before you did the sprag clutch, than it should now. Good luck and keep us posted.
     

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  3. Jim DeFina

    Jim DeFina New Member

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    Yea, I don’t think I had to remove the PG for the starter clutch, but did for whatever reason. So I went back inside the crankcase to have a look to see what I might have done wrong. And unfortunately everything looks in order. I do wonder though the magnetic pickups on the PG, what are they picking up their signal from within the starter clutch ?
    Know this may help me understand:
    1) why I’m not getting spark in cylinder #1
    2) why an engine that has spark on 3 cylinders doesn’t even sputter start.

    Is my timing off? I don’t think you can out the starter clutch assembly onto the engine crank wrong. It only fits one way!

    Looking for answers in SF
    Thx,
    Jim


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  4. vfrMatt86

    vfrMatt86 New Member

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    Well.... on the outer steel casing of the starter clutch various raised tabs have been pressed in and the pulse generator pick up the signals from them as they pass by.

    The starter clutch can't really go on in an incorrect orientation, granted you put all the pieces you took out back in the same spot. Did you use loctite on the bolts? Have any pictures of your starter clutch?

    Is your battery fully charged? Are the plugs wet after you turn it over for a bit?
     
  5. Jim DeFina

    Jim DeFina New Member

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    Yea. Thanks for the reply. Yes when I opened it back up I made sure everything was in the right place . All good . Yes, I used locktite on the 3 clutch bolts, the battery has 12.5 on a trickle charge. The plugs are wet after attempting to start.
    I can pull the cover again tmrrw and shoot some pics/. Probably will need to get another gasket for the crankcase cover before I put it all back together …


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  6. vfrMatt86

    vfrMatt86 New Member

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    Hmm

    It's not ideal but it's times like this I just walk away for a minute and slow it down.

    Start small and work up sort of thing.

    1. Check your fuses
    2. Re-test coil wire and the coil for cylinder 1. Run a direct 12v wire from the bat to the positive terminal on the coil. And a direct wire to a ground. See if that gives you spark. Swap out the plug wires on cyl 1 and 2 see if that gives you spark. Maybe she's testing ok but it's not ok. :shrug:
    3. Take off the seat, tank, faring's and visually inspect the wire harness for pinched / cut or disconnected wires.
    4. Pull the fuel line apart after the pump before the carbs.. see if she's spitting fuel.
    5. Drop that oil again (into a clean container so that you can re-use it) and pop open that ride side cover. Take some pics. A fresh set of eyes might see something that you're missing.
    6. Re-trace your steps with that pulse generator, visually inspecting the wires and/or testing it with your multimeter.


    Make it fun and productive to take it all apart again. Maybe buy some ebc springs for your clutch while you're waiting for that gasket to come in. Or just use some gasket maker. I use the permatex stuff on almost everything. Never had a leak. Maybe do some de-greasing and cleaning while it's all exposed. She'll love you back for it and you might find your problem as you detail it. :)

    Keep at it. You'll figure it out.
     
  7. Jim DeFina

    Jim DeFina New Member

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    Hey, thanks for the encouraging words, ya this is suppose to be fun damit ! Lol.
    I have taken a couple days away . Hope to come at it with fresh eyes and clear mind on over the weekend…. Will try and get some pics too


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  8. Jim DeFina

    Jim DeFina New Member

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    Well I finally was able to spend some time with the bike the other night. I read again in the manual how to install and install the PGRU later mentioned something about putting the wiring harness ( for the PG) bracket behind the pick up sensors which I checked and I did. I was rotating the clutch to see the metal tabs as it rotated and came upon one flattening tab! Wow see pic below I’m sure that has some with some affect on the pick up! So I guess I need a new starter pack? [​IMG]
    [​IMG]


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  9. squirrelman

    squirrelman Member

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    if ya lean the bike a little to the right (like against a wall) there's no need to drain the oil.
     
  10. Jim DeFina

    Jim DeFina New Member

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    How so? Leaning to the right the oil fills the crankcase cover …?


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  11. TOE CUTTER

    TOE CUTTER Mullet Man

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    I think VFR Matt86 may have a spare unit of that vintage on his hands.
     
  12. RllwJoe

    RllwJoe Member

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    I would be temped to try and "straighten out" the mashed tab! What do you have to loose? As long as it doesn't end up taller than it should be.

    It looks like you could get a small sharp punch started under the edge and carefully reshape it.
     
  13. Jim DeFina

    Jim DeFina New Member

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    Yes, I tried to wedge that little f*clear up. And got to where I thought it was similar to the nipples in height, but was rather jagged. And in the end didn’t fix my issue.


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  14. Jim DeFina

    Jim DeFina New Member

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    VFR Matt86. I will give him a shout
    Thx !


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  15. squirrelman

    squirrelman Member

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    ass backwards, jim. i'ma gettin old.
     
  16. Jim DeFina

    Jim DeFina New Member

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    I’ve followed the advice of other members and went to Partzilla for a new starter clutch. At the time of placing the order they had a few in stock, I ordered with expedited shipping. Well. 3 days later I get an email from partzilla telling me the part is back ordered with not ETA on when the next ones will be available…. Aaarrrrg!
    Anybody know of another parts supply source for VFR’s? Specifically the starter clutch ?
    Meanwhile the sun in shining and my bike sits in the garage :-(

    Thanks you,
    Jim


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  17. vfrMatt86

    vfrMatt86 New Member

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