Make sure the flat ground side of the washer is what is butting up to the clutch hub. You will probably be able to feel the drag of the washer just pushing it in with your fingers and turning it.
There can only be a couple issues there.
1. the washer is up side down, or the shaft is worn somehow where the washer butts, or the collar that the basket needle bearing isnt seating properly...
The big thrust washer basically sandwiches the basket. The clearance is set by the inner collar and the washer. If the washers clamping area is damaged or the basket is some how coming off the drive gear...something isn't correctly assembled or has been compromised some how.
Thanks , I was under the impression that the gears had to line up 100% so I was worried when they didn't . Im going to get a new washer , bearing , collar and hub since mine shows signs of wear anyways and go from there . If it still does the same you might see a 08 CRF450R in the obituaries
That's kinda what I was going to do but was not sure if maybe there was maybe a certain load on the main shaft bearing or something like that. If I torque it down to 48 lbs it will spin freely but at the OEM spec 59 lbs it binds. I have some wear on the clutch hub so Im going to replace it .
Edited by crfloco, 02 July 2012 - 10:57 AM.