My kickstart lever on my dt400 snapped the bolt which holds the lever onto the base. I am trying to remove base but it will come only about half way off then comes to a stop. I tried widening the clamp gap and also trying to easy out the snapped lever bolt as it may be hitting the shaft. I tried lots of wd40. The east out bolt remover I have had poor drill bits as having hard time drilling into the bolt. I have attached photos but not sure of photo attachment is working? Any ideas? I do not mind if I have the sacrifice the kickstarter on it nor. I would buy a replacement. Bike is fairly rough but is a good woods bike. Thanks.

easy out is (in my opinion) the only way to get it out as you already know the splines are not the length of the shaft but has a separation so that the the bolt will slide through and fit into it's spot and with the bolt in place the brake lever will not be able to slide off.
Now I could be totally wrong about having to remove the bolt.

edit: kick starter.. DUH!

The broken bolt needs to be removed in order to slide the kickstarter off the splined shaft. There is a relief machined into the splined shaft and the bolt stud passes thru that relief which prevents the kickstarter from falling off the shaft even if the bolt is loose. Hope that makes sense….. You need to continue your efforts with an easy out.

Edit:
Dogboy and I were responding at the same time……

Is there enough room to get a drill in there, so that you can just drill it out? Bolt material shouldn't be too hard, start off at say 3mm drill bit and work up in 1mm increments.

To post photos you need to use a third party host.

If your drill bit isn't making headway, use a cobalt bit or titanium coated bit if someone put a hardened bolt in there.

Thanks for your replies. I will invest in stronger drill bits and continue on. Thanks again much appreciated.
 

Another option is to carefully take a grinder or cut off wheel to the boss the threaded part of the bolt is in.  It's not too hard to cut into the boss until what's left of the bolt is free.  

I'm pretty sure the DT400 has a two piece starter with a replaceable boss that is still available new Yamaha OEM and aftermarket.  583-15621-00-00

www.partzilla.com/product/yamaha/583-15621-00-00  

Many new/used on ebay.

Or this new lever should work.  www.mikesxs.net/yamaha-xs650-kick-starte...splined-knuckle.html