Join Date: Jun 2003
Location: Montreal, QC, Canada
After re-reading your message, I see that you are working too hard - you posted this:
"Bolted up trans to intermediate housing with little problem after aligning clutch plate by eye and leaving the 6 allen bolts loose. Second try and trans went on nicely."
There is no need to do this in 2 steps, in most cases you can just use the push rod with a long socket of proper size. See attached picture.
Sorry, I am not in garage right now so I do not have the exact size of inside diameter of splines on friction plate. You should find a tube or a long socket of proper size with a bit of creativity ;-)
John (Montreal, CANADA)
K1200RS (2002 IceBlue/Red - 96,000 miles)