The splines are buggered. As y'all know, a pretty common problem with old Japanese bikes.
This shaft is off an RD200, but everything done here applies to about all Japanese kick starters.
Here's the video that made me think this was doable.
Ordered a single wheel knurling tool that showed up today. Straight knurl, with wheels at .5, 1.0, 1.5 and 2.0 mm pitch. It's too large for my AXA holders, so a little moddin' is in order. Two reasons I didn't get one to fit my holders... first, I wanted something kinda beefy lookin. The ones to fit mine looked like matchstick toys compared to this one. And second, I couldn't find one with 2mm pitch unless I handed over a kings ransom.
I quickly discovered the axle circlip was spring loaded to the flight ready position.
My local Ace hardware has 'em, so....
To make it fit my holders, I cut out a piece of 1/4" by 1" steel and welded it to the bottom of the knurler.
Even used a little gun blue to feed the OCD for corrosion protection. 
Put it on the tool holder and found out that A, I didn't take everything into account when I dreamed this up, and B... I got pretty friggin' lucky.
The knurling wheel was way too high with the adjustment knob down pretty low. Started raising it (dropping the tool) and quickly figured out I was prolly short on adjustment. Finally just raised the adjustment all the way up so it's not touching anything and let the AXA block bottom out.
Sumbitch if I ain't but just 5 or 10 thou high.
Here's the adjustment wheel all the way up...
And here's a dead center stuck in the axle hole...
And here's a view through the hole. Looks to be maybe 5 or 10 thou high. I figure I'll get a good 5 to 10 thou flex out if the Atlas when the wheel's under load, so I could actually be dead on. I think I'll shave a good 10 thou off the bottom of the block just in case... On the other hand... might just give it a go as it sits. But.... goin' on the assumption I've used up my share of luck for the day, I'm callin' it.
This shaft is off an RD200, but everything done here applies to about all Japanese kick starters.
Here's the video that made me think this was doable.
Ordered a single wheel knurling tool that showed up today. Straight knurl, with wheels at .5, 1.0, 1.5 and 2.0 mm pitch. It's too large for my AXA holders, so a little moddin' is in order. Two reasons I didn't get one to fit my holders... first, I wanted something kinda beefy lookin. The ones to fit mine looked like matchstick toys compared to this one. And second, I couldn't find one with 2mm pitch unless I handed over a kings ransom.
I quickly discovered the axle circlip was spring loaded to the flight ready position.
My local Ace hardware has 'em, so....
To make it fit my holders, I cut out a piece of 1/4" by 1" steel and welded it to the bottom of the knurler.
Even used a little gun blue
Put it on the tool holder and found out that A, I didn't take everything into account when I dreamed this up, and B... I got pretty friggin' lucky.
The knurling wheel was way too high with the adjustment knob down pretty low. Started raising it (dropping the tool) and quickly figured out I was prolly short on adjustment. Finally just raised the adjustment all the way up so it's not touching anything and let the AXA block bottom out.
Sumbitch if I ain't but just 5 or 10 thou high.
Here's the adjustment wheel all the way up...
And here's a dead center stuck in the axle hole...
And here's a view through the hole. Looks to be maybe 5 or 10 thou high. I figure I'll get a good 5 to 10 thou flex out if the Atlas when the wheel's under load, so I could actually be dead on. I think I'll shave a good 10 thou off the bottom of the block just in case... On the other hand... might just give it a go as it sits. But.... goin' on the assumption I've used up my share of luck for the day, I'm callin' it.
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