Probably all the ones we had break were purely through neglected chain mantenance on farm bikes & may have just climbed off the rear sprocket from being very loose then bunched up at front. But chains were pretty rubbish back then, maybe not original but cheapy replacements.

You can get much better chain today...  a standard RK chain is probably twice as strong as the same chain back then.

Rust is the big killer...  Do not run a rusty chain even if you clean it up and lube it.  Chains are case hardened and rust can destroy the hardening.  Metal underneath is soft so chain breaks,  Rust is probably the #1 cause of failure. 

 

Used to work on a coupe of jeeps for the Aussi's when I was in Viet Nam. They would bring them to our motor pool for repair. They would bring me Castlemaine and Courage beer all the time. Good people!

Ok, got the new brg and washer and the thrust washer that was missing today. Put 
the new parts in and the good news is that the end play in the inner clutch basket
was gone, the bad news is that it wouldn't hardly turn when snugged up. Measured
the washer the DPO had put in that was against the shaft brg that is in the case and
found it measured 2mm thick. Called the dealer and had him measure one for me and
it was 3mm thick. But the problem is also the od. The correct part number for the very
inner thrust number is 30mm od and the washer they had in it was 38.something. It
was hitting on the brg retainer. The brg they had installed there is actually the one
that goes between the inner and outer baskets. I am thinking the stars will align after
I get this thrust washer tomorrow. I will post some pics and measurements for future
reference for the group when I start putting it together.

Ok, not sure if I'm on the same page but have had them bind up when tightening the nut & even to the point of not turning at all. Whenever that happened I used to give the kick gear on the back of the clutch a wipe to increase end clearance. I did try removing the gear wich is pressed over the bush extension then grinding a little off the dogs then fitting it back on so its in the dog slots deeper as it never fully home. Dogs are home but gear has a little clearance, so bit of the dogs let it go in that fraction more. BUT--with my luck the damn gear picked up on the bush on the way back on causing grief. So gave up that idea & just gave it a crude grind. I'm sure you could do a better job if you need to. Just lacking end clearance--running clearance. Keep it in mind, that's all. & from what I understand your saying--the thickness of the Big Washer won't affect end clearance on the spacer. Happy to be wrong though.
Sorry edit edit spelling etc.

I think the big problem now is the thrust washer that goes against the case
brg is to big od and is hitting the retainer. I will post a pic up for you. BTW,
what adhesive did you use on the clutch basket o ring?

Yes, the washer you had against the bearing in the case was actually the missing washer that belonged to the flat thrust bearing.

Pictures of the correct washers to fix the problem.  If you look at the edge of the retainer you can see where the washer that was installed in the wrong location was rubbing on it. 

Correct first washer to be installed behind clutch basket.

Collar with lube hole out