[Freesponge]

On my 66 RE the kick start doesn't engage well when its at the very top, Usually I can only get a good kick off when Its around the middle only allowing 100 degrees of motion instead of 200 degrees. Occasionally if It fiddle with it I can get it to engage but often it will slip past and catch farther down. Anybody run into this sort of problem, is there an easy fix or do I have to replace the unit?

[The Garbone]

Assuming your talking about a a 4spd box for a 350 or 500 bullet my guess is it would be the spingle  (32),  layshaft bush  (33) or pawl , all or one being worn causing the alignment to be off and  the reduced range of motion.    Just a guess.

http://www.hitchcocksmotorcycles.com/partsbooks/pages/984/Gearbox

[rotorwrench]

All the RE twins & singles that used the Albion 4-speed gearbox were made in similar fashion. The high gear with the ratchet teeth on the inside, may have wear on the teeth. The pawl has a little bitty spring and plunger to keep it ingaged to the high gear inner teeth. If the little spring breaks, it gives the symptoms you mention. That or a worn out pawl or spindle as was previously mentioned. All in all, it's not too hard to fix in comparison to other tasks.