Mark, where have you been hiding. Yep needs the washer, as usual lol i was trying to think what i'd try if i was stuck, to make it work. Look at ebay uk 265430888240. Granted it's a "74 & has the flat bearing against the washer. But interesting looking at how deep the plates sit into the basket considering there's 5 plates as normal. Just trying the number it only seems to work under ebay/uk.

ebay 284851366363 says 3mm thick if you can believe it. But says DT175mx so don't know if will fit.

Morley, my patience has been short lately and it wasn't clear what the problem is here...  Still isn't clear to me and we're flying mostly blind.  Question was how to stack discs but most people don't ask that unless there is a problem?  And from the first post it also sounds like there is a problem with the talk about loving the bike and not giving up on it?  

I'm also feeling a bit "dense" lately...  posts and questions might be presented crystal clear but I'm just not understanding? 

As we know, stack order doesn't really matter that much anyway...  best on early models without toothed pressure plate to end up with steel on last.  But many are assembled incorrectly and work fine. 

As more pictures are posted something does look off...  and yes, washer is needed. 

1976 might have similar paint scheme but it has a lot of changes.  Clutch is one of them.  I think I see a "525-" number on the aluminum basket in one of the new pictures which I believe is the shorter basket first used on the off-road competition models to allow Yamaha to build a slightly narrower engine.  It uses 3mm friction discs instead of the 4mm used from 69-75.  Other than thickness, the frictions are interchangeable. 

For the narrower clutch to work, 1976 has a unique one year only transmission shaft that is noticeably "stepped" compared to the earlier models.  So you can't use a 76 clutch on an earlier model very easily... unless maybe you change the shaft or find/make a different bushing.  I still can't tell enough from the pictures so just guessing.  The next generation 175 engine (monoshock) went to the smaller diameter shaft of the competition models...  different bearing in case... and kept the shorter clutch basket with 3mm frictions.  So 69-75 = 4mm.  76 on = 3mm

 

 



 

Im working all day tomorrow...so Monday il pop the washer 
back in....il send pictures of the spline and basket and how
thick each friction plate is.... what is the effect if i take a friction plate out??
and what is the effect if its slightly over when all stacked in??

As usual Mark you're a wealth of information!

Wouldn't the engine number answer a lot of questions?
As Mark noticed primary driven gear is 525-16???
 

Yes, engine number...  at least the prefix...  would be extremely helpful. 

     

  

This is how it looks with washer back in and all fiber
Plates in

That's a 1976 DT175C.  Not a 1975. 

What thickness discs did you buy?  Pretty sure they should be 3mm and as I've said a few times the 1975 had 4mm.