Putting my '92 Blade engine back together (CBR900RRN) and got to the clutch reassembly. The outer basket has a sprung gear wheel and is fighting me on fitting. Basically you need to rotate one of the gear wheels so both sets of teeth line up so it can be pushed all the way onto the main shaft. See ... https://www.fowlersparts.co.uk/parts...-1992-e/clutch .... for a picture - I'm talking about part #2. The shop manual says nothing. I have a Haynes manual and that is very vague about using a flat blade screwdriver. Don't want to force anything or be too heavy handed until I know what the technique is for putting it back on.

Anyone got any pointers or sites that describe/show how?

Ta

 

You should be able to use the bolt on the end of the crankshaft to rotate the gear ever so slightly to help align the gears. Did you loosen the cam chain tensioner?

 

Had a look and I see what you mean, I'll try again when I manage to get time. As for the CCT the whole top end is still to be fitted so not applicable here ... :-)

 

Didn't work. However I finally did it by following this video ....


.... It isn't a Blade clutch but the construction is very similar. Basically the relevant bit is about leaving out the 'sleeve' (actually part #5 in the Fowlers link in the OP). The bearing is left in on the Blade, as it's a press fit. This allows you enough 'wiggle' room' to align the gears and it slips on with hardly any effort! Just remember to make sure that the oil pump rotates with the clutch basket before you go any further .....

Hope that helps someone else.