The pinion post is geared/splined 360* at both ends, it doesn't matter where it seats. The adjustment is made by rotating the arm on the spline, after the cover is installed. (edit to add: the clutch release rack is only notched on one side and the teeth must be rotated forward before putting the clutch cover on. It sticks out of the clutch hub and engages the pinion post.) There is something that catches while installing the cover (I don't remember what), just wiggle it around until it seats; including rocking the arm back and forth. I found that I could keep the cover 'flat to the case' by gently tightening the bolts with my fingers.
Do not remove the pinion post.
2004 DR650: 62,605 miles
SUZUKI DR650SE INFORMATION INDEX
Originally Posted by Threewheelbonnie
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
ER70S-2 screwed with this post 04-23-2012 at 10:43 AM