I got the clutch all sorted out the other day and finally had a chance to put it all together ( thought that would have happened last Sunday.....Nope) so here are some photos of it and a short Vid of it starting.
The sound is not very good because I had supercross playing on the tv and it was louder than I thought. What I said at the beggining is that I was actually starting it for the second time but the first time was only 30 seconds before. It took 4 kicks for it to fire up and the carb is really close to where it needs to be.
Here is the link for vid. I started this project in August of 2011 so to this date it has taken 11 months.
I have ordered a couple new to me side panels and they should show up in the next week or so. Now I will be down to hunting for Graphics and a mud flap.
This is the concave washer. Its not a huge cup but it is there.
Finally resolved the problem with the clutch hub nut popping the threads off at under 30 ftlbs. There is a concave washer on top of a spline washer that i am guessing is supposed to be somewhat of a lock washer that just puts pressure on the nut to keep it from spinning. Personally I like the fold over washer set up better. So I was putting the concave washer in with the top of the cup toward the nut. There is no direction in the manual or that I could find online that says which way it goes. Well I ruined two of the nuts then turned the washer over so the cup of the washers outside edges contact the nut then torqued it down...Boom, it works.
I also purchased a new to me clutch basket that was in much better condition then the one that I had. As you can see in the photo the edges of the new basket have very little wear on them compared to the photo in the last post showing the old unit.
Ready to put the covers back on and fill with oil.
The sound is not very good because I had supercross playing on the tv and it was louder than I thought. What I said at the beggining is that I was actually starting it for the second time but the first time was only 30 seconds before. It took 4 kicks for it to fire up and the carb is really close to where it needs to be. 
Finally resolved the problem with the clutch hub nut popping the threads off at under 30 ftlbs. There is a concave washer on top of a spline washer that i am guessing is supposed to be somewhat of a lock washer that just puts pressure on the nut to keep it from spinning. Personally I like the fold over washer set up better. So I was putting the concave washer in with the top of the cup toward the nut. There is no direction in the manual or that I could find online that says which way it goes. Well I ruined two of the nuts then turned the washer over so the cup of the washers outside edges contact the nut then torqued it down...Boom, it works.
