Post by wayne on Oct 24, 2022 0:13:26 GMT -5
The kick start story:
Ever wondered about the kickstart? Heard they originally shipped without one (Urban myth?). Aren’t they just GT? And what gives with the gooseneck version?
Everything you could imagine about the kick start. This is a copy of a post on the old forum by Sam Costanzo in 2009 (and if you’ve stumbled on this from the internet, Sam was contracted by Suzuki to work with them on the RE5. Nothing below is an Urban Myth).
The pictures and text in italics have been added for this post, they weren't part of Sam's original article.
Over to Sam:
In reference to the Kick Start lever discussion, I have checked my notes and would like to share the following information.
A Kick Starter was on all RX, RP and RE pre production models.The early kick starter had a double bend, a “Z” to it. It’s often referred to as a “goose neck” (see owner’s manual REM front cover p33 or Service Manual p148, fig 16-4 and 16-5 or Parts Catalog p23, no. 17, part no. 26300-31001 (Edit: p23, no 16, part no. 26300-31002 in later parts books)).
To save you the trouble, here it is as Sam says, from the parts book, early or late editions, they all show the "gooseneck", almost certainly not what's actually on your bike. Note: only the pictured early edition shows the optional rubber cap #16 as in the page below
The double bend kick starter was originally approved for the RE5M full production.
Early brochures showed the RE5 with the "approved" gooseneck kickstarter
However, Suzuki ran into problems with delivery from outside RE5 source suppliers. Among them was the kick starter. In view of a late delivery and just prior to the start of production on the “M” model, Suzuki decided that the use of a kick starter on the new, tight rotary engine would be most difficult for the average rider. It would almost take the use of both feet to turn the engine over. Plus, since all RE5s came standard with a heavy-duty, powerful Nippondenso electric starter, there was no need for a kick starter. Suzuki Marketing zeroed in on this decision and immediately offered a kick starter as an option for $10.75 (see RE5 Parts Book p17, #23 = kick starter = optional EDIT: the "optional" notation appears in the early M model only parts book. In the later parts books, while it's still pictured as a gooseneck, it's standard equipment).
Further notes reveal that Suzuki states from frame number block #10054 to #10753, some kick start levers were not installed on RE5 units prior to engine #10753. “Some”?... in all reality meant that “all” 700 RE5 units were manufactured and shipped without the kick starters. Note that a protective, black rubber cap bearing an embossed Suzuki “S” was affixed over the exposed kick start spline shaft (see Parts Book p23, no. 16, #26391-37000 Edit: once again, this only appears in the early parts book, refer the parts book page pictured above).
Early magazine review from Japan sans kickstart
Continuing on, out of the first shipment of 700 RE5s in late 1974, 285 units went to dealers both large and small, predicated on initial pre-production orders. Among the largest dealers noted indicates the following:
1. Percy Coleman & Co. Ltd., New Zealand
2. Heron Suzuki Ltd., GB
3. Franchaise Suzuki S.A., France
4. Suzuki Italia S.P.A., Italy
5. Suzuki-Motor-G.M.B.H., West Germany
6. B.V. Nimagnederland
7. US Suzuki Motor Corp. of Los Angeles, California
The largest dealer and shipment of 415 units went to #7, US Suzuki Motor Corp. The RE5s came in (8) large containers, plus two more full of spare parts. Upon arrival at the Los Angeles dock, customs officials along with Suzuki reps inspected the containers of the new RE5 rotaries. Customs had questions and doubts on the machine and did not release them into the US.
They immediately called in the DOTSB (Department of Transportation Safety Board) for a second opinion or clearance. The DOTSB inspected and viewed the new RE5s and was quite impressed with them and talked with Suzuki reps from some length of time about the advanced engineering and marvelled at the engine’s simplicity. They agreed this was the new power source for future machines. This was a good conversation, and everyone got along very well.
Suzuki reps felt they were only one step away from loading the containers on trucks. However, both the DOTSB and customs inspectors denied US Suzuki from importing the motorcycles into the US. They flatly rejected them as unsafe for public use. The reason: no kick starters! A kick starter was mandatory on all US imported motorcycles at the time as a safety back up in case the electric starter did not work thus leaving the rider stranded. Upon hearing this, the Suzuki reps turned white as a sheet and were dumbfounded. Nothing was said for a minute, then one rep asked “is there anything we can do?”. The inspectors said “yes, they can grant a special safety variance contingent release”. Hearing this, Suzuki reps entered immediately into an official agreement with customs and DOTSB that kick starters would be furnished to all US RE5 dealers and would be installed on Rotaries prior to any public sales. The signing of this agreement allowed the release from import into the US all 415 RE5s the following day.
In keeping with the agreement, a special Rotary alert notice was sent out by US Suzuki via telex, mail and area reps. It was also followed up by a special bulletin RE1, dated Dec. 20, 1974 (p2 no.2). By mid January, 1975, all 415 RE5s were distributed by authorized Rotary dealers across the US.
However, between Dec. 20, 1974 and Jan. 15, 1975, almost a month later, no kick starters were received by dealers and their RE5 customers were getting a little impatient and upset to say the least. They could not pick up their new Rotaries. In some cases orders were cancelled and deposits returned.
Upset with Suzuki for non-deliverance of the kick starters and not wanting to lose a sale, many dealers took matters into their own hands and pulled new GT750 kick start levers off the shelf. In some cases, they took them off GT750s in stock and installed them on the RE5s. Oddly enough, by the end of January, Suzuki issued a dealer notice no. 121 stating that the kick starter lever #26300-31000 for the GT750 could be used as a substitute for the RE5 and that dealer use of the off-shelf levers would be reimbursed at $7 each.
The first delivery of gooseneck starters (part #26300-31001) to US Suzuki finally came in mid February. It consisted of only 100 assemblies with the balance to follow. Approximately 30 were shipped to nearby California dealers, but it was soon found out that the quality of manufacture and chrome plating was second rate. Plus, upon installation, it was found that it was very difficult to mount and align it on the spline shaft. This problem was brought to Suzuki’s attention, and within days a “do not install” service order was sent to all RE5 dealers that received the gooseneck kick starters. Suzuki then sent out GT750 kick starters as replacements (#26300-31002).
The "Gooseneck". This is the correct way for this lever to sit. This is a pre-13000 frame. The kickstart spline was designed for this lever
The factory fitted "GT" style. This is also a pre-13000 frame. Note how rearward this lever sits. The spline alignment was not designed for the GT lever but it worked nevertheless
Suzuki finally redesigned the spline. Somewhere after Frame #13000 the new spline allowed the GT lever to sit more "naturally"
Once the redesigned kick start spline was on the production line, the originally intended Gooseneck no longer sits "right" (compare to the blue M above)
Other important, random kick start notes are as follows:
- there was no follow up by customs or DOTSB after the 415 RE5 Rotaries were allowed into the US.
- in fact, some dealers did sell RE5s without the kick starter and left the rubber, protective cap on (#26391-37000).
- some dealers did retrofit the gooseneck kick starters on RE5s not to lose a sale.
- from frame #10754 until the end of production, a new, longer GT750-style kick start (#26300-37001) was factory installed on all M&A models.
- today the double-bend gooseneck starter and the rubber protective cap are much sought after by Rotary enthusiasts and collectors.
- No notes are available on how foreign dealers or customs handled their kick start issues.
How the foreign dealers may have handled the early no-kickstart bikes? A UK advertisement
More confirmation that, at least in the UK, no kickstart wasn't an issue. Thanks to member HGH 770N for the pictures and it's his bike in the magazine
And how much was a UK kickstart? Member HGH 770N bought one for the above bike. Recall that they were initially an option and note these are UK Pounds
- Kick start Recap:
26300-31000
26300-31001
26300-31002
26300-37000
The way the kick starter problem unfolded and how it was addressed results in the RE5 being correct with any of the above four part numbers.
Sam
Ever wondered about the kickstart? Heard they originally shipped without one (Urban myth?). Aren’t they just GT? And what gives with the gooseneck version?
Everything you could imagine about the kick start. This is a copy of a post on the old forum by Sam Costanzo in 2009 (and if you’ve stumbled on this from the internet, Sam was contracted by Suzuki to work with them on the RE5. Nothing below is an Urban Myth).
The pictures and text in italics have been added for this post, they weren't part of Sam's original article.
Over to Sam:
In reference to the Kick Start lever discussion, I have checked my notes and would like to share the following information.
A Kick Starter was on all RX, RP and RE pre production models.The early kick starter had a double bend, a “Z” to it. It’s often referred to as a “goose neck” (see owner’s manual REM front cover p33 or Service Manual p148, fig 16-4 and 16-5 or Parts Catalog p23, no. 17, part no. 26300-31001 (Edit: p23, no 16, part no. 26300-31002 in later parts books)).
To save you the trouble, here it is as Sam says, from the parts book, early or late editions, they all show the "gooseneck", almost certainly not what's actually on your bike. Note: only the pictured early edition shows the optional rubber cap #16 as in the page below
The double bend kick starter was originally approved for the RE5M full production.
Early brochures showed the RE5 with the "approved" gooseneck kickstarter
However, Suzuki ran into problems with delivery from outside RE5 source suppliers. Among them was the kick starter. In view of a late delivery and just prior to the start of production on the “M” model, Suzuki decided that the use of a kick starter on the new, tight rotary engine would be most difficult for the average rider. It would almost take the use of both feet to turn the engine over. Plus, since all RE5s came standard with a heavy-duty, powerful Nippondenso electric starter, there was no need for a kick starter. Suzuki Marketing zeroed in on this decision and immediately offered a kick starter as an option for $10.75 (see RE5 Parts Book p17, #23 = kick starter = optional EDIT: the "optional" notation appears in the early M model only parts book. In the later parts books, while it's still pictured as a gooseneck, it's standard equipment).
Further notes reveal that Suzuki states from frame number block #10054 to #10753, some kick start levers were not installed on RE5 units prior to engine #10753. “Some”?... in all reality meant that “all” 700 RE5 units were manufactured and shipped without the kick starters. Note that a protective, black rubber cap bearing an embossed Suzuki “S” was affixed over the exposed kick start spline shaft (see Parts Book p23, no. 16, #26391-37000 Edit: once again, this only appears in the early parts book, refer the parts book page pictured above).
Early magazine review from Japan sans kickstart
Continuing on, out of the first shipment of 700 RE5s in late 1974, 285 units went to dealers both large and small, predicated on initial pre-production orders. Among the largest dealers noted indicates the following:
1. Percy Coleman & Co. Ltd., New Zealand
2. Heron Suzuki Ltd., GB
3. Franchaise Suzuki S.A., France
4. Suzuki Italia S.P.A., Italy
5. Suzuki-Motor-G.M.B.H., West Germany
6. B.V. Nimagnederland
7. US Suzuki Motor Corp. of Los Angeles, California
The largest dealer and shipment of 415 units went to #7, US Suzuki Motor Corp. The RE5s came in (8) large containers, plus two more full of spare parts. Upon arrival at the Los Angeles dock, customs officials along with Suzuki reps inspected the containers of the new RE5 rotaries. Customs had questions and doubts on the machine and did not release them into the US.
They immediately called in the DOTSB (Department of Transportation Safety Board) for a second opinion or clearance. The DOTSB inspected and viewed the new RE5s and was quite impressed with them and talked with Suzuki reps from some length of time about the advanced engineering and marvelled at the engine’s simplicity. They agreed this was the new power source for future machines. This was a good conversation, and everyone got along very well.
Suzuki reps felt they were only one step away from loading the containers on trucks. However, both the DOTSB and customs inspectors denied US Suzuki from importing the motorcycles into the US. They flatly rejected them as unsafe for public use. The reason: no kick starters! A kick starter was mandatory on all US imported motorcycles at the time as a safety back up in case the electric starter did not work thus leaving the rider stranded. Upon hearing this, the Suzuki reps turned white as a sheet and were dumbfounded. Nothing was said for a minute, then one rep asked “is there anything we can do?”. The inspectors said “yes, they can grant a special safety variance contingent release”. Hearing this, Suzuki reps entered immediately into an official agreement with customs and DOTSB that kick starters would be furnished to all US RE5 dealers and would be installed on Rotaries prior to any public sales. The signing of this agreement allowed the release from import into the US all 415 RE5s the following day.
In keeping with the agreement, a special Rotary alert notice was sent out by US Suzuki via telex, mail and area reps. It was also followed up by a special bulletin RE1, dated Dec. 20, 1974 (p2 no.2). By mid January, 1975, all 415 RE5s were distributed by authorized Rotary dealers across the US.
However, between Dec. 20, 1974 and Jan. 15, 1975, almost a month later, no kick starters were received by dealers and their RE5 customers were getting a little impatient and upset to say the least. They could not pick up their new Rotaries. In some cases orders were cancelled and deposits returned.
Upset with Suzuki for non-deliverance of the kick starters and not wanting to lose a sale, many dealers took matters into their own hands and pulled new GT750 kick start levers off the shelf. In some cases, they took them off GT750s in stock and installed them on the RE5s. Oddly enough, by the end of January, Suzuki issued a dealer notice no. 121 stating that the kick starter lever #26300-31000 for the GT750 could be used as a substitute for the RE5 and that dealer use of the off-shelf levers would be reimbursed at $7 each.
The first delivery of gooseneck starters (part #26300-31001) to US Suzuki finally came in mid February. It consisted of only 100 assemblies with the balance to follow. Approximately 30 were shipped to nearby California dealers, but it was soon found out that the quality of manufacture and chrome plating was second rate. Plus, upon installation, it was found that it was very difficult to mount and align it on the spline shaft. This problem was brought to Suzuki’s attention, and within days a “do not install” service order was sent to all RE5 dealers that received the gooseneck kick starters. Suzuki then sent out GT750 kick starters as replacements (#26300-31002).
The "Gooseneck". This is the correct way for this lever to sit. This is a pre-13000 frame. The kickstart spline was designed for this lever
The factory fitted "GT" style. This is also a pre-13000 frame. Note how rearward this lever sits. The spline alignment was not designed for the GT lever but it worked nevertheless
Suzuki finally redesigned the spline. Somewhere after Frame #13000 the new spline allowed the GT lever to sit more "naturally"
Once the redesigned kick start spline was on the production line, the originally intended Gooseneck no longer sits "right" (compare to the blue M above)
Other important, random kick start notes are as follows:
- there was no follow up by customs or DOTSB after the 415 RE5 Rotaries were allowed into the US.
- in fact, some dealers did sell RE5s without the kick starter and left the rubber, protective cap on (#26391-37000).
- some dealers did retrofit the gooseneck kick starters on RE5s not to lose a sale.
- from frame #10754 until the end of production, a new, longer GT750-style kick start (#26300-37001) was factory installed on all M&A models.
- today the double-bend gooseneck starter and the rubber protective cap are much sought after by Rotary enthusiasts and collectors.
- No notes are available on how foreign dealers or customs handled their kick start issues.
How the foreign dealers may have handled the early no-kickstart bikes? A UK advertisement
More confirmation that, at least in the UK, no kickstart wasn't an issue. Thanks to member HGH 770N for the pictures and it's his bike in the magazine
And how much was a UK kickstart? Member HGH 770N bought one for the above bike. Recall that they were initially an option and note these are UK Pounds
- Kick start Recap:
26300-31000
26300-31001
26300-31002
26300-37000
The way the kick starter problem unfolded and how it was addressed results in the RE5 being correct with any of the above four part numbers.
Sam
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