tvscum Posted July 8, 2017 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! Share this post Link to post Share on other sites
tvscum Posted July 9, 2017 (edited) 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. Edited July 9, 2017 by tvscum 1 Share this post Link to post Share on other sites
zach_507 Posted July 9, 2017 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! 1 Share this post Link to post Share on other sites
notoriousE-R-I-C My Ride Posted July 9, 2017 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. 1 Share this post Link to post Share on other sites
Tryingoutdirt Posted July 9, 2017 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 2 Share this post Link to post Share on other sites
vicxr400 Posted July 9, 2017 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 Share this post Link to post Share on other sites
tvscum Posted July 9, 2017 (edited) 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 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 July 9, 2017 by tvscum typo Share this post Link to post Share on other sites
tvscum Posted July 9, 2017 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. 1 Share this post Link to post Share on other sites
WWalker Posted July 9, 2017 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. 2 Share this post Link to post Share on other sites
tvscum Posted July 9, 2017 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. Share this post Link to post Share on other sites
FFMan Posted July 9, 2017 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. 1 Share this post Link to post Share on other sites
tvscum Posted July 9, 2017 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. Share this post Link to post Share on other sites
tvscum Posted July 10, 2017 Washer is still unidentified 1 Share this post Link to post Share on other sites
firstplacephoto Posted July 10, 2017 what pipe is that tn video,sounds pretty quiet! 1 Share this post Link to post Share on other sites
SkInM4n Posted July 10, 2017 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 Skin Share this post Link to post Share on other sites
FFMan Posted July 10, 2017 think of the weight saving :-) 1 Share this post Link to post Share on other sites
SkInM4n Posted July 10, 2017 Just now, FFMan said: think of the weight saving :-) LMAO! Yep, perfromance upgrade! Skin Share this post Link to post Share on other sites
tvscum Posted July 10, 2017 5 hours ago, firstplacephoto said: what pipe is that tn video,sounds pretty quiet! It's this pipe with the XRsOnly logo removed. Logo comes right off. They also have headers (not cheap). http://www.xrsonly.com/xrs-only-exhaust-pipe-honda-xr400r-stainless-steel-cone-tip Share this post Link to post Share on other sites
vicxr400 Posted July 10, 2017 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! 1 Share this post Link to post Share on other sites
