stubborn kick-start cotter

[V500]

Radco in the Vintage Motorcyclists' Workshop suggested filing a taper oh a HT bolt but my feeling is this wouldn't leave enough thread engagement. Never tried it though. TBH I loathe cotter pints - splines/serrations have their issues as well but I prefer them.

Good job we're all different. The only issue I've ever had with cotters is when they're too stubbornly in place, but I'll live with that rather than stripped/worn splines any day. Cotter cranks are cheap and reliable and don't wear.
What Radco suggested may work as a get-you-home temporary repair but the cotter thread isn't concentric to the shaft, so won't be an easy or very effective adaption.

[neil1964]

I agree with @iansoady

You are less likely to do damage by drilling the guts of the cotter pin out first, you will probably not have to drill it all out as the heat (and whatever cooling fluid you use when drilling) will loosen it.
As your cotter is installed the wrong way round drilling the body (vs the thread will be easiest, I think).
I've managed to buy stainless steel oversize cotters for one of my bikes as it is actually the K/S hole that has gone slightly oval vs the shaft worn, should probably get a new lever, but it seems to be holding for now.

[hoogerbooger]

UPDATE

proved pretty easy with a the ball joint splitter pictured. Only had to remove the foot-rest to get a position where the force was fairly straight and the splitter didn't try to wiggle it's way out of place.

I'm guessing it would have come out with a hammer and punch, without too much welly, if I had been brave enough.

Quite surprising to me is how small the dints are on the cotter face. Can feel with the finger nail but very slight. Shaft recess looks nice and unmarked, but then that is presumably much harder.

I have a spare, but looks like I can use this one again. I presume I try to dress out the small dints on a sheet of emery paper on glass or carefully file......and put it back in nut forward this time.

[DAVE BRADY]

Hi,

Be very careful cleaning up the face as it does not take much too slack and it will go too far through.

Dave.

[hoogerbooger]

noted. It already didn't have much head showing.

[neil1964]

noted. It already didn't have much head showing.

I'd always fit a new cotter pin.
If it is a long way through why not buy one of the O/s ones.  Easily available. Draganfly do them.