Kickstart Splines Tight

[Rich_j]

I've got a kickstart arm that's a pretty tight fit on the gearbox splines. The only way way I can get it on or off is to knock a screwdriver into the slot to open it up. Not too bad getting it on as I can prepare it off the bike, getting it off is another thing. I don't want to start pounding at it and the gearbox and driving a screwdriver in damages the chrome and chews up the slot.
Anyone got any top tips?

 

[concours]

I've got a kickstart arm that's a pretty tight fit on the gearbox splines. The only way way I can get it on or off is to knock a screwdriver into the slot to open it up. Not too bad getting it on as I can prepare it off the bike, getting it off is another thing. I don't want to start pounding at it and the gearbox and driving a screwdriver in damages the chrome and chews up the slot.
Anyone got any top tips?

Remove 5 splines on each side of the split.

 

[kommando]

And you want it tight, removing the splines helps but also make sure you use a good hardened bolt to tighten it back up. Once you have sloppy splines then both the shaft and kickstart will need replacing not long after.

 

[nortonmargie]

I have the sloppy spline on the kickstart lever problem. Have a replacement and going to work on it this afternoon. Mechanic thought the shaft was OK, would cross fingers but it is hard to work on bike with crossed fingers

 

[B+Bogus]

And you want it tight, removing the splines helps but also make sure you use a good hardened bolt to tighten it back up. Once you have sloppy splines then both the shaft and kickstart will need replacing not long after.

They definitely clamp better with a few splines removed either side of the split.
Ducati did this in the early '70s.

 

[robs ss]

Put a thin blade (paint scraper?) in the slot and wind the bolt in from the threaded side. Will spread the K/S.

 

[MichaelB]

Put a thin blade (paint scraper?) in the slot and wind the bolt in from the threaded side. Will spread the K/S.

BRILLIANT!!!!