Can't get the kick start lever off

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Ratboiler

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New lever bolted up once, bolt is out and lever has partially come off exposing the serrated spline up against the gearbox and groove for the bolt, but can't get it over the final serrated spline.
I have opened the slot but am cautious about hammering in a wedge to force it open even more.
Any tips please.
 
I've had this problem too. Just hammer it open more ... with a wedge/chisel ( GENTLY) .. no other way really. Also use a puller, to make sure it is coming straight off. Don't want to "bugger up" those kick start shaft splines.
 
Yeah I use a chisel or a BIG screwdriver to widen the gap. Avoid damaging the splines. The useful manuals are no help on this one. Nortons.
 
Ratboiler said:
New lever bolted up once, bolt is out and lever has partially come off exposing the serrated spline up against the gearbox and groove for the bolt, but can't get it over the final serrated spline.
I have opened the slot but am cautious about hammering in a wedge to force it open even more.
Any tips please.
Click to expand...
I posted this a couple of months ago - may help (and minimise damage!) Advice - RGM kickstarter removal
 
Thank you that sounds a first class way to get it off, I knew I was right to leave it and ask for help.
 
The problem is a little play, so the splines wear on the shaft, but not in the middle where no splines are. The play is most cases caused by a bolt that has not enough thread, so a thck or even 2 washers so the lever can be tightened to no play.
 
Will do it's off now thanks, just about to change the kick start oil seal the only seal I did not change as it looked too difficult......little did I know.
Going to ptfe tape the spline when I put the cover back on.
 
Ratboiler said:
Will do it's off now thanks, just about to change the kick start oil seal the only seal I did not change as it looked too difficult......little did I know.
Going to ptfe tape the spline when I put the cover back on.
Click to expand...
No need . Grade 8 bolt.
 
Ratboiler said:
Will do it's off now thanks, just about to change the kick start oil seal the only seal I did not change as it looked too difficult......little did I know.
Going to ptfe tape the spline when I put the cover back on.
Click to expand...
One thing that's worth checking before it's back on...
Make sure there are no spline "teeth" immediately beside the "split". If there are, grind them off with dremel or similar. 2-3 teeth either side of the split should be gone.
It will be these teeth (close to the split) that prevent proper tension being achieved all the way around the spline. Will be tight initially but will soon slacken.
I've noticed some kick-start levers that have this fault.
 
That's what I noticed.
I tightened the bolt fully home when i had the gearbox to pieces and when i came to remove the bolt it was not tight that's for sure.
 
Ratboiler said:
That's what I noticed.
I tightened the bolt fully home when i had the gearbox to pieces and when i came to remove the bolt it was not tight that's for sure.
Click to expand...
Any kicker bolt less than grade 8 will stretch. This is crucial .
 
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Same problem here. After opening the slot a bit, I used a pickle fork behind it just like separating an automobile ball joint. 2 whacks 90 degrees apart and it was off. In the states many auto parts stores will loan you the tool for free.
 
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