Clutch lock up after rebuild

[mikeley]

When I stripped my rd125lc mk1 engine I was missing a very thin concaved washer that is the first item to go behind the clutch basket. It sits behind the tiny locating dowel and up against the bearing.
Because I wanted to get the rebuild spot on I purchased a new one from Yamaha and fitted it upon rebuild. The next item is a spacer that has a portion missing to sit over the dowel, then the clutch outer basket, then another spacer then the inner basket, lock washer and nut.
Unfortunately for me I didn't check that the inner basket was still free to turn after I torqued it up. I rebuilt everything and started the bike today after just a few kicks, yippee I thought???
Then I pulled in the clutch and kicked it into first gear and the bike just lurched forward and stalled. I tried everything to get the clutch to disengage but it wouldn't.
After taking the clutch cover off to investigate I've found that if I build it up how I found it (without the thin concaved washer) everything is still free to turn, however built up correctly with the thin concave washer installed as per the book, the inner basket locks up solid and will not turn?
Has anyone else had this problem?
If your in the process of a rebuild make sure you check the inner clutch basket turns before you build up everything around it.
Now I need another clutch cover gasket before I can ride the bloody thing, lol.

[Eyrey1]

tip
i use a bit of oil or grease and coat the new gaskets so they dont stick to the cases and dont tear so you can re use them

[gazbeemer]

Michael. I had a similar problem with mine. Didnt lock up solid but did go quite tight and difficult to turn. Try a few sharp taps on the end of the shaft with a nylon hammer as your tightening the nut up i think it helps to settle the shafts in the bearings. It worked for me and now they spin free. Worth a try. Gary