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Hi all,
My kickstart 'shaft' (the bit the lever clamps to) is rounded a bit and is chewing through the cotter pins. It still works ok but has a bit of play.

Is there a common quick fix for this? can I put soem weld on it and re-dress the face? Is it easy to replace?
or.... could i fabricate a cotter pin to fit the rounded-ness

cheers
derek
 

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I would imagine you could get away with a little dressing down of the notch but I wouldn't go very far or the cotter won't lock in anymore. It will be cheaper than a new shaft if it works. If it doesn't work, you were going to need a shaft anyway. Make sure the nut is properly touqued on reassembly.
 

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Take the shaft out of the outer gearbox case, build it up with weld, re-dress carefully, and put it all back together. Worked for me.
 
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