So I tore into the XS, after my morning ride on the CBR(!!!!), shopping, honey-do's(couldn't ask me yesterday, could she!!!), and my new tool wall I slapped together this morning.
After CAREFULLY removing the cover-the gasket was still in one piece, yay!- it dawned on me that the clutch basket has to come off, and also the shift arm! Not a happy chap, I tell you!
So after undoing the six screws that hold the basket together, I tried to undo the bolt, but the basket just spins!!! I could not for the life of me remember how I tightened it! Checked the build thread, and realised I didn't write(type) it down. Bugger........
After doing the dishes, searching the forum on how people did it as I don't have the tool to do the job, I suddenly came up with a BRILLIANT idea on how to do it!!
Here's how I did it!!
I added a nut under the mole grips so they stick out further, thereby locking the basket in place!
Sorry about the blurry pic, it looked fine when I took it! I guess not!!
Anyhoo, once the clutch was off, it was pretty straightforward really. Instead of removing the shift lever, I just removed the spring, and pushed the arm down.
Then I undid the little bolts holding the plate down, remover the one closest to the plate completey, but leaving the other one in but only just biting into the thread. This allowed me to move the plate out the way enough so the shaft can be accessed.
I took some Neodium magnets I have, a whole bunch of them actually! They only 5mmx5mmx1mm but quite strong! about 20 of them stacked up made for a nice magnetic pull! Pushed it up against the shaft, and carefully pulled. It only came out about 5mm, but that was enough to get my nose pliers in there and carefully pull a little further until I saw the notch!!
I then twisted it until it was where it had to be, and then tightened down the nuts on the plate, replaced the spring on the arm, put clutch back on(I decided to check the plates, and turn them so all the bevelled edges lie on the same side), tighten the bolts, and the screws, close the lid, and finish it off!
Best of all, I dreaded the kickstart would come out/fall out, just didn't want to do it all over again!!! But it DIDN'T!!! It stayed in throughout all of this!!
Well chuffed with myself! It was surpisingly quick as well, only just under two hours! Felt a lot easier too, like I almost knew what I was doing!!!
Thanks again guys for spotting it, I do appreciate it, this is also part of the reason for me doing this, so that the guru's can spot my booboo's!!!
Here is the proof, I forgot to post it!!!