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Well it turns out that the replacement starter motor I bought turns the wrong way which confused the hell out of me.
So working back from the flywheel I realised that all was not well so the final solution was to replace the starter motor innards with those of the old one using the brushes from the new one.
It had partially shagged the sprag clutch gear in the process so chopped 2 inches from the retaining spring and rejoined it.
She fired up first time last night and what a joy to hear her again.
Now I have the side stand light on permanently so will be carry out the small modification to that tonight. She'll be back on the road by the weekend keeping all my fingers crossed.

It's good when a plan comes together !

Glad you've got it sorted ..... now what starter motor is it that we need to avoid ?

Excellent - thought you would get there in the end.

D-Rider wrote:It's good when a plan comes together !

Glad you've got it sorted ..... now what starter motor is it that we need to avoid ?

TBH you wouldn't know by looking at it that there was any difference from the original. Same numbers on the casing etc.

So before fitting it make sure that you bench test it to make sure direction is clockwise as you look at the gear end.

And you're not as glad as me that it's sorted.

That's great news Andy!
Was a bit sad to hear you sounding really down and talking about getting rid, as I know you would never even consider this if the job situation was better.
Get back on it and remind yourself that it rides even better than it sounds, and have a really good weekend!
There's nothing better than a ride on a Falco to seriously cheer you up, especially on those roads up in your area.

That's great mate, a bit strange the starter turning the wrong way, but a good fettle to get is sorted.

are the British ones right turn drives
Glad your sorted mate

good to hear you bike is running , did not know the starters turn different directions, i must make a note of that in case mt sprag need replaced

D-Rider , did you know this ?

joecrx wrote:good to hear you bike is running , did not know the starters turn different directions, i must make a note of that in case mt sprag need replaced

D-Rider , did you know this ?

Nope !

i thought you being the guru of falcos would have came accros this just kidding never heard of this even on Af1 , , just wondering why , futuras , millies , falcoes etc dont have the same sterter and sprag , turning in the same direction ,

I'm a dab hand at the old sprag clutch fix/replacement now having done it twice on my own bike and once on a mille.

This weekend should see her all back together and tickety boo ready for this years MOT complete with 130dB horn from Acumen

I'll be doing an oil and filter change, clutch and brake fluid changes, new pads and the sidestand switch mod, sync the cylinders adjust throttle bodies and then ride the beast.

Looking forward to leaving for the NW200 on 11th May.

Falcoholic wrote:I'm a dab hand at the old sprag clutch fix/replacement now having done it twice on my own bike and once on a mille.

I'll be doing an oil and filter change, clutch and brake fluid changes, new pads and the sidestand switch mod, sync the cylinders adjust throttle bodies and then ride the beast.

May I ask two quick questions?

Regarding the spring adjustment (ok, cutting) on the sprag clutch, as an option to replacing it, how long does that usually last as a fix? Is it fairly robust and worth it? I know new sprags (and associated parts) cost silly money, but just wondering if the spring fix really is viable long term?

Also, what do you mean by adjust the throttle bodies? Adjust them how? Making sure they open evenly? I didn't think there was much to do there.