Kickstart Lever won't tighten enough

I have a dirtbike and I recently had to remove the transmission cover to do some work with the clutch. In doing so I removed the kickstart lever from the shaft, which was held tightly onto the shaft by one bolt. I am trying to reinstall this lever, but it doesn't matter how many times I tighten this bolt down, the lever still slips after a few kicks. I've replaced the bolt thinking it was simply stripped, but nothing has worked. The bolt isn't slipping and the threads on the shaft and the lever don't seem very worn. Is there a home fix anyone can recommend for this?

when you tighten the bolt is there still a gap in the opening? if not the shaft or lever spline might be worn. sometimes if that is the problem you can put lever in vise to close gap and recut with a hacksaw, might have to do it more than one time. not a perfect fix but it isnt a perfect world

When in doubt use lock tight.

cut it like the last post said and drill the kick start lever bolt hole to make it one size larger diameter and then use a threw bolt with nut and washer and lock washer in the originals place you will get a better bite that way on the shaft

I don't exactly follow what you mean by "cut it with a hacksaw" and unfortunately the lever is closed on one end so I can't use a threw bolt and nut combo. That does sound like a really good idea, I just don't have the tools. Could one of you expound on the whole cutting thing?

use the open hole as a gide and continue to drill it all the way threw till the bit goes to the other side . then put the bolt threw it. if the kicker is split were you clamp it at the trany the hack saw is for you to take material off one side of the mounting portion of the kick rod . so that you can clamp down on it more with out the to halves coming together then you will be able to torque down on the threw bolt follow me ?