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[Andy C]

Measured things up - I/D of the O ring fitted in the case is approx 18mm shaft O/D is 19mm so the seal has to compress 0.5mm radially.

Biggest problem (partly my fault) was that the O rings for the kickstart shaft were dry, as was the gearbox lever oil seal.

I say partly my fault because I had the cover off once to change one of the clutch pushrods and should have lubricated the O rings and oil seal when I had it apart, although the assumption was that they would have been lubricated when put together originally.

Anyway I lubed the kickstart O rings and shaft and temporarilly re fitted the cover and I found that the kickstart lever would return under it's own spring pressure with a little help from me, so I guess that once I have kicked the bike up a few times all will be well.

[Andy C]

Final update from me.

After liberally greasing the kickstart shaft and re fitting the cover the kickstart returned under it's own steam and was easy enough to press down with the clutch pulled in.

Put the oil in and it no longer returns - clearly down to the viscosity of the oil, and it being cold I guess.

Guess that once it has been used a decent amount it will free up.