I dug into it and here’s what I found. It all looks good to me although this washer fell out with the cover but I believe it goes on the kickstart shaft? I’m going to stop here for the night and let you guys look at the pictures and see if you were anything obviously wrong before I take the clutch pack out. I know you can’t tell much now but I’ll pull the clutch pack Wednesday.

Washer must be from there. Is it a good fit on the shaft as looks big ID but maybe an illusion. Looks like it needs to sit into the spring a little but OD looks 'big'. I don't know, guessing without being there. Just thought maybe someone has substituted a washer from something else but probably is correct. Can't be from anywhere else. Then again i just looked at the parts pic being a suspicious type & shows what i thought it should be. So now i'm wondering if that washer is from the clutch thrust flat bearing & been misplaced to there. They may have replaced the clutch flat bearing which comes with a flat thin washer & might've used the old bearing washer to do the job. We wait with baited breath untill clutch is apart. If clutch is slipping--as in reving up but not speeding up--it'll be just glazed up plates so replace them & leave out the rubber spreader rings if still there. Aftermarket plates may not leave room for them to be fitted anyway--& not needed.

No10 

No17 bearing!!. Doesn't show the washer "but is part of it". No18 in the pic "isn't it" & doubt they could use it as it'd be way too thick & doubt case would go on. I see the pic doesn't show the kick gear on the back of the clutch but doesn't matter for this story.

It looks like the basket/primary gear is too deep relative to the drive gear on the crankshaft. But it may be an optical illusion in the picture. Did you remove the basket/primary gear?

Thank you, that washer does fit on the kick shaft pretty well and if it isn’t supposed to go there I must have put it there as I was the last one in there. Will I need to replace the clutch plates even if I just changed them and probably haven’t ridden 10 miles with them since I haven’t got it to operate correctly? Yes I did take the clutch basket out when I did the new crank seals. 

I know this is simple, but did you include the ball bearing in the actuation mechanism?

I sure did… the second time.

Sorry, no you won't have to replace the plates if just been done. I'm half asleep & should have read back a few pages. So question still remains as to why its not working. Better pull the clutch hub off & lay everything out in order of disassembling so we can see what you have--& to see if that washer has come from the flat bearing & things like that.

What 1971DT250 says in post #35 could point to the washer i mentioned being missing from flat bearing so the basket could sit back a little. If that was the case though, the basket with gear should be able to move out & in a couple of mm or more than normal if has clearance.