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Unidentified 6.5mm washer after XR400 lower end rebuild

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I rebuilt my lower end and just finished putting it all together and bolted the cylinder head on -- and then I found this unidentified washer on my parts table.  It must have fallen off some bigger part that I did not bag.  It looks like a 6.5 mm ID, THICK washer (not a copper sealing washer).  Could it be this part (below) that holds the plastic cam chain tensioner arm in place, called a Drum Stopper Washer?  I see photos of this washer but it does not appear to be THICK.

WASHER, DRUM STOPPER
Part# 90417-360-000

Nightmare scenario here!  It measure to be a 6.5mm ID washer, but I suppose it would also fit on a 6mm bolt.  It definitely will not fit on a 8mm bolt.  Measurements are on the attached photo.

Any help from the xr400 experts appreciated!

 

 

 

 

washer.jpg

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I think it's this part, if anybody has their XR400 apart please take a photo and post.  At any rate, I've ordered the part to see if it's the same, #11 below.

 

washer2.jpg

Edited by tvscum
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Wish I could help you but I work on 2 strokes so I dont have to deal with this confusing stuff lol. One time my buddy asked me to help rebuild his 4 stroke. When I took the valve cover off I just wanted to give up. Hope you get it all sorted out and riding again!

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You gotta have those schematics in your face while youre in the motor. Now youll have to open up and look and see what's missing. Thats a much faster and much more precise and much less emotionally antagonizing routine than guessing and looking at the schematic way too late. If it hasnt ran yet. Open it back up. Gaskets are fine.

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The bright side is that if it is that washer then you only have to take off the side case cover and you won't have to split the case again

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Did you remove the shift drum??? it may go under the shift drum stopper

# On DiagramPrice Per ItemQTY In BasketNotesDetails

124211-KCY-670FORK R GEAR SHIFTx1$97.98

224221-KCY-670FORK, CENTER GEARSHIFTx1$97.98

324231-KCY-670FORK L GEAR SHIFTx1$97.98

424241-KCZ-000SHAFT, GEARSHIFT FORK GUIDEx1$22.57

524300-KCY-670DRUM COMP., GEARSHIFTx1$165.03

624411-KCZ-000CAM GEAR SHIFTx1$18.93

724430-KF0-000STOPPER COMP., GEARSHIFT DRUMx1$16.14

824435-KCY-670SPRING, SHIFT DRUM STOPPERx1$5.94

924610-KCY-671SPINDLE COMP., GEARSHIFTx1$85.11

1024624-MT3-000SPRING, GEARSHIFT RESETx1$3.86

1124651-KF0-013SPRING, GEARSHIFT RETURNx1$7.47

1224652-028-000PIN, SHIFT RETURN SPRINGx1$10.78

1390022-MG8-000PIVOT, SHIFT DRUM STOPPER ARMx1$6.41

1490417-360-000WASHER DRUMx1$4.80...........................................this one

1591202-965-003OIL SEAL 14X28X7x1$10.26

1694510-14000CIR CLIP, EXTERNAL, 14x2$1.75

1795701-06020-00BOLT FLANGE.6X2x1$2.61

1896220-30098ROLLER 3X8.5x1$0.70

 

shift drum xr400.png

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2 hours ago, vicxr400 said:

Did you remove the shift drum??? it may go under the shift drum stopper

# On DiagramPrice Per ItemQTY In BasketNotesDetails

124211-KCY-670FORK R GEAR SHIFTx1$97.98

224221-KCY-670FORK, CENTER GEARSHIFTx1$97.98

324231-KCY-670FORK L GEAR SHIFTx1$97.98

424241-KCZ-000SHAFT, GEARSHIFT FORK GUIDEx1$22.57

524300-KCY-670DRUM COMP., GEARSHIFTx1$165.03

624411-KCZ-000CAM GEAR SHIFTx1$18.93

724430-KF0-000STOPPER COMP., GEARSHIFT DRUMx1$16.14

824435-KCY-670SPRING, SHIFT DRUM STOPPERx1$5.94

924610-KCY-671SPINDLE COMP., GEARSHIFTx1$85.11

1024624-MT3-000SPRING, GEARSHIFT RESETx1$3.86

1124651-KF0-013SPRING, GEARSHIFT RETURNx1$7.47

1224652-028-000PIN, SHIFT RETURN SPRINGx1$10.78

1390022-MG8-000PIVOT, SHIFT DRUM STOPPER ARMx1$6.41

1490417-360-000WASHER DRUMx1$4.80...........................................this one

1591202-965-003OIL SEAL 14X28X7x1$10.26

1694510-14000CIR CLIP, EXTERNAL, 14x2$1.75

1795701-06020-00BOLT FLANGE.6X2x1$2.61

1896220-30098ROLLER 3X8.5x1$0.70

 

shift drum xr400.png

Nice catch, thanks for that!  I did remove the shift drum, except I worked on the shift drum on a separate bench from where I found the random washer so it probably is not that one.

Note... #14 washer on your diagram above is the exact same part number as #11 in my diagram above.  They are the same washer.  So I will wait for the part to arrive and see if it is the same.  It is a pretty THICK washer so fairly unique.  It's such a cheap part that it's worth buying before diving back in.

#11 will require clutch removal.  #14 in your diagram can be installed with the clutch in place.

Tryingoutdirt... yes, hopefully just a right side case cover removal :-)

Still hoping someone has a XR400 apart in their garage and can snap a photo of the washer and post.  Thanks all!

Edited by tvscum
typo

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Update:  THIS IS NOT THE RIGHT WASHER.  I dove back in the right side.  (I could not wait for that washer to arrive in the mail). I removed #14 from vicxr400's diagram above and it is a thin washer, not a thick one.  Therefore, #11 is not the right one either, as they are the same part number.

Back to square one.  I am starting to think this is just some random spacer that fell off a part.  I will continue to search the parts diagrams.  

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I have been there done that. Put together my XR 200 complete bottom and top end. Engine was in frame then I noticed a couple random washers/spacers. One was a spacer for the transmission and another was for the cam. Had to completely tear it down, split the cases, and start all over again from square one. Thank goodness I caught it when I did. Nothing like putting and entire bottom and top end together two times! The amount of profanity coming from the garage was at record levels.

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Thanks guys.  I have confirmed washer #11 and #14 are installed and they are flat washers.  Putting it back together now.  Thick washer/spacer is still a mystery.

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that washer you have looks like alloy, or is it just the picture ?

I've just split the cases on an xr250 and there are no alloy parts inside.

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2 hours ago, FFMan said:

that washer you have looks like alloy, or is it just the picture ?

I've just split the cases on an xr250 and there are no alloy parts inside.

That's what I was thinking.  

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7 hours ago, tvscum said:

Washer is still unidentified

Well from that video it seems promising that there is no imminent danger. Started right up, idled fine, revved fine, appeared to pull fine when in gear...I think it's time to hang that washer on a cord and wear it as a necklace :thumbsup:

Skin

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think of the weight saving :-)

 

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Just now, FFMan said:

think of the weight saving :-)

 

LMAO! Yep, perfromance upgrade! 

Skin

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OK cool I did not want to give you a bum steer.... I have a 98 xr400 and in all my work on it iv never seen a washer like that. I went looking through the parts diagrams and could only find that one as another option as far as I can remember the washer under the cam chain follower is a steped washer. im starting to wonder if the washer belongs?  I was lying in bed thinking about it was the washer coverd in oil??? indicating it was from the inside of the engine?? dunno great that it runs and hope that IF that washer is from the engine it does not cause any damage without it...... keep that beast thumpin!

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