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The red box in the picture shows that the semicircular metal cutout on the bolt for the perpendicular shaft of the lock is in the way

enter image description here

I know this is not a manufacturing defect because the earlier Kwikset has the same colliding structure. So what am I misunderstanding here and how to install this part correctly?

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The "cutout" where you're getting interference is a normal part of the latch mechanism. It needs to slide/retract slightly when you first assemble the pieces.

Here is a nice video demonstration:

https://youtu.be/bsgpomUQcy0?t=410

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  • i don't believe that were mentioned anywhere in the instructions. Commented Dec 15, 2021 at 7:52

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