wpiruss
Plastic
- Joined
- Dec 1, 2011
- Location
- Massachusetts, USA
Hello,
I'm looking for ideas on how to reduce the diameter of the splined hole in motorcycle kickstart lever. The aftermarket exhaust that is installed on the bike interferes with the stock lever. I have found a replacement that will solve the interference issue but the splined hole is about 1mm too big in diameter. Even with the lock screw tightened completely the new lever is loose on the shaft. The shaft is 13.5mm in diameter. The replacement lever has a minimum diameter of 14.5mm
It seems one way to approach this is to remove more material from the gap that allows the spline hole to contract around the shaft when the lock screw is tightened but I'm concerned that the screw itself will no longer line up correctly and end up cross threaded.
Another approach would be to somehow add material to reduce the size of the opening- maybe a shim or worse case welding the hole closed and then re-machining/broaching the splines.
The bike in question is a classic '72 Honda. I cannot buy another stock kickstart lever to modify. I do not wish to cut up, bend or modify the original.
Your thoughts are welcome, thanks!
I'm looking for ideas on how to reduce the diameter of the splined hole in motorcycle kickstart lever. The aftermarket exhaust that is installed on the bike interferes with the stock lever. I have found a replacement that will solve the interference issue but the splined hole is about 1mm too big in diameter. Even with the lock screw tightened completely the new lever is loose on the shaft. The shaft is 13.5mm in diameter. The replacement lever has a minimum diameter of 14.5mm
It seems one way to approach this is to remove more material from the gap that allows the spline hole to contract around the shaft when the lock screw is tightened but I'm concerned that the screw itself will no longer line up correctly and end up cross threaded.
Another approach would be to somehow add material to reduce the size of the opening- maybe a shim or worse case welding the hole closed and then re-machining/broaching the splines.
The bike in question is a classic '72 Honda. I cannot buy another stock kickstart lever to modify. I do not wish to cut up, bend or modify the original.
Your thoughts are welcome, thanks!