Kick start lever removal, kz650 b

I feel stupid, I unlocked bolt nr 10, but I can’t slid the arm of the splints, it releases the arm so I can (only) move it out 10 mm but then (some how) it hits a invisible hard stop. Any suggestions before I start using force?

 

Did you completely remove the bolt?

Yes, completely. 

Looking at the schematic drawing I just can’t imagine what causes the stop. The stop feels very firm ‘metal to metal’ after moving out the first 15-20 mm or so. 

I took mine off years ago and have it handy to slip on and off if needed. Try gently prying the slot open with a screw driver while pulling off.

Could be a burr or some crud. A generous application of your favorite penetrating oil and spreading the clamp a bit as KZB2 650 suggests, may do the trick.

Thank you all, I had to use a lot of force but eventually i came off. I used a nut as a distance on the shaft end allowing me to pry out the boss without applying force on the gears etc on the inside. 

After examination I think the reason for the bad jam is that the bolt holding the boss had bad groves making correct tightening impossible - leading to play between boss and shaft, and years of kickstarting led to a slight twisting of the splines inside the boss, as there are two sets of groves on the shaft it became a problem when trying to get it off as the inner part of the boss no longer aligned perfectly with the outer part of the shaft creating a gridlock. 

Pic

Video 

Any pics of the kick starter shaft???

Shaft!
 

Any pictures of kickstart return spring? or part number?

Thanks
Narendra

Diagram and part numbers.

www.partzilla.com/catalog/kawasaki/motor...ickstarter-mechanism