RL250 Extra Washer after Split Case

[MountainTrails]

After splitting the case to replace the crank seals, I have an extra washer!   It's 17 X 33 X 1.5 mm.  With a 17mm through hole, I assume it's off the transmission.   In reference to fig 8 (Transmission) of the parts manual.  The only washers on the parts list are Item 33 a thinner (1mm) washer and item 34 a conical washer are both present.  I did not go past the bearing so missing item 16 is ruled out.  

I can see wear marks on the washer that would correspond to the small diameter portion of the conical washer.  When things are installed per the parts manual illustration, there is no slop when installing the cir-clip on the end, and installation of this clip is not possible with this thicker washer substituted for the thinner washer.  Is it possible to compress the conical washer so installation is possible?  Where does this mystery washer go?  Any and all help is greatly appreciated.

[kurtas]

I would start by lining it up with the other bearings in the case.

it may be a shim that was added to get the correct end float on a shaft.

[MountainTrails]

Hi Kurtis, thank you for the reply.  I had given that thought.  With a 17mm thru hole, the only shaft small enough is the transmission shaft.  I've attached a scan of the parts list for the transmission.  Item 21 (the shaft) is the only diameter it fits on.  The bearing you are suggesting is item 22.  I know that the part was on the outside of this referenced bearing, as I was stripping parts to make it easier for the mechanic to separate the case for me, and do the seal work and return to me assembled minus the parts I took off.  There are only 2 washers (and 1 snap ring) on that side of the bearing.  Those are items 33 and 34.  Both of those items seem to be in place.  Item 33 is a similar washer but is only 1mm thick.  Item 34 is a conical washer (not flat).  I'm convinced that the washer came from this assemble, but it's not shown, and all parts accounted for.  Can anyone confirm that item 34 is conical?

I still have assembly issues if I add this washer, as then the snap ring won't go on.  So did this washer come from else where?  There are 2 washers of similar nature shown on the Kick Starter Parts List.  I have attached that schematic.  They are Items 4 and 15.  Both of these washers are present on my assembly.  Could it have been an additional spacer here?  Does anyone have the dimensions of items 4 and 15?  PN's 08211-17342 and 08212-20361 respectively.  From the pictures I've been able to find it looks similar to item 4 (08211-17342).

 

Kick Starter shaft.pdf Transmission parts.pdf

[MountainTrails]

An update:  I took all of the right rife off again and reassembled.  I took off 3 washers, but can only get 2 washers back on.  I have no idea what washer is what PN, but no matter how I ordered things, I couldn't get a 3 washers back on the shaft for the snap ring to fit.  If I left off the thinnest one (1 mm thick), I could get it to assemble.  So that's where I am going forward.  Still hopping someone might have this side apart and might help identify what washer is what PN.

 

As I moved on to attach the clutch side cover, I found that the kick starter was binding up when I fully tightened all the screws, especially those near this shaft.  The seal was binding.  I took the cover back off looking for clues as to why.  I was guessing the cover might have a slight warpage, so I took some marker to the edge and moved it on a flat piece of metal.  This showed a slight warp, so I taped down sandpaper to the metal and sanded to make it even.  It took a lot of sanding, but eventually got this even.  I then found this had NO EFFECT.  I've tried tightening things in different sequences, but nothing changes.  

 

Anyone with any experience having this happen?  I've had this cover off multiple times prior without incident, what changed.  When the cover screws are fully tightened, the starter shaft is binding so bad that it is very difficult to kick through.