Went to start car. Didn't fire, noticed the LED on the MS showing cold engine wasn't lit. Assumed I had dislodged a spade connector from the temperature sensor. Carried on cranking.
Engine missfired. Stopped cranking.
Tried cranking again and starter just whirred. Damn, hit it with hammer, just whirred.
Turns out that the ECU thought the engine was warm, so supplied less fuel on startup. This cause missfire which resulted in the engine trying to go the wrong way which broke a gear on the back of the clutch (starter gear).
Had to take out the clutch (actually took out 3 clutches as needed to find a replacement gear), not difficult on a motorcycle engine with air-tools. You can even do it with the engine oil in place as long as you can tip the engine a few degrees.
Anyway, it is all back together now. Also removing the dB killer has sorted out the boost. Getting a nice 8psi from 6kRPM (better than the 7kRPMbefore), and this can be controlled nicely with the boost controller. Aim now is to get a steady 8.25psi (155kPa) from 6kRPM to the red line with sensible fueling. Then need to work on the ignition timing and on the acceleration enrichment (which is rubbish at the moment).
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