/5-/6 gearboxes

[George Ryals]

I have kick started a 1974 R90/6 in a /2 conversion with no electric starter 2 or 3 times a day for years with no problems. The key is to be sure the kicker gears are engaged properly before kicking. Push down on the kicker an inch or so to make sure the quadrant gear is engaged and turning the engine. Then a push on the lever to crank the engine. Don't just jump on the lever to begin.

[Major Softie]

I have kick started a 1974 R90/6 in a /2 conversion with no electric starter 2 or 3 times a day for years with no problems. The key is to be sure the kicker gears are engaged properly before kicking. Push down on the kicker an inch or so to make sure the quadrant gear is engaged and turning the engine. Then a push on the lever to crank the engine. Don't just jump on the lever to begin.

George, 4-speed or 5-speed? The 4-speed's kick-starter is not at issue.

[robert]

I have kick started a 1974 R90/6 in a /2 conversion with no electric starter 2 or 3 times a day for years with no problems. The key is to be sure the kicker gears are engaged properly before kicking. Push down on the kicker an inch or so to make sure the quadrant gear is engaged and turning the engine. Then a push on the lever to crank the engine. Don't just jump on the lever to begin.

George, 4-speed or 5-speed? The 4-speed's kick-starter is not at issue.

The kickstart idler gear shaft loses its press fit and falls into the works.

[George Ryals]

Robert, I had that happen on a 4 speed. Luckily no damage was done to the trans. I popped it open, drilled and tapped the end of the shaft and with a coat of red lock tight, bolt and washer, all is good again.

[robert]

Robert, I had that happen on a 4 speed. Luckily no damage was done to the trans. I popped it open, drilled and tapped the end of the shaft and with a coat of red lock tight, bolt and washer, all is good again.

I have repaired several that way. Really loose ones can be knurled to help tighten them. Good idea to check and make that repair any time the cover is off.

[jbensaab]

Can the five speed be repaired that way as well? Or is it a lost cause?

[jbensaab]

My plan is to just get it running and assess it's condition from there. not using the kick start as it feels really weird. I have changed all the oils and realigned the swing arm.