Well, yesterday it was finished. The cotter pin went in way too far and would need replacing, but it worked. However, there was an itch...
I suppose I am a bit obsessive, but I couldn't put up with having to remake the cotter because I had machined the shaft wrongly. I filled the slot up with weld.
A few minutes later, I had re-machined the slot; the shaft is 3/4" within the kickstart lever and the slot has a maximum depth of 0.150" - the easiest way to measure this accurately is from the bottom of the cotter slot to the opposite side of the 0.75" diameter, so you measure 0.600". The slot is bang on the correct depth, and the 0.375" cotter pin fits perfectly.
All I need to do now is cut the spare length off the cotter pin and radius the end.
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