Originally Posted by jzeiler
It needs to be pretty straight so the starter will slide into its proper place in the intermediate housing. You did pull the clutch alignment tool out, right?
I did... LoL
I thought the clutch was supposed to move freely, hence he instruction to turn the alignment tool during assembly. What I did not realize is that it is supposed to snug up as the bolts are tightened.
John Z to the rescue! In less time than it takes a human heart to beat, he asked which way the diaphragm spring was facing. Of course I had it in backwards, its curve matching that of the clutch housing. Doh!
No harm... yet. When I pulled the transmission away, the bike, which was suspended from its rear frame, decided to lay over and engage my head. After I realized that I dropped the phone, I picked it up and told John I was ok and I laughed. IMPORTANT SAFETY TIP: Suspend the frame from two equidistant points with individual straps or chains to keep the bike balanced, especially when working alone! (see image below)
So, I woke up Suzanne (she works nights) and after she inspected my boo boo and I put a couple of steri-strips on it, she helped me right the bike, place it on the jack stands, and I added an additional strap in concordance with the important safety tip, above. She is back asleep, thankfully, and I am back to the beast. Never say quit... quitting is for quitters!
Thanks, John Z, for another great save! Sure am glad that I did not get the starter splines lined up when reinstalling the transmission. If it were not for that, I might have had it all back together before realizing that the clutch spring was incorrectly installed!