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Oh God NO! Random washer found after lower end rebuild

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I rebuilt my lower end and just finished putting it all together and bolted the cylinder head on -- and then I found this unidentified washer on my parts table.  It must have fallen off some bigger part that I did not bag.  It looks like a 6.5 mm ID, THICK washer (not a copper sealing washer).  Could it be this part (below) that holds the plastic cam chain tensioner arm in place, called a Drum Stopper Washer?  I see photos of this washer online but it does not appear to be THICK like my random one.

WASHER, DRUM STOPPER
Part# 90417-360-000

Nightmare scenario here!  It measure to be a 6.5mm ID washer, but I suppose it would also fit on a 6mm bolt.  It definitely will not fit on a 8mm bolt.  Measurements are on the attached photo.

Any help from the xr400 experts appreciated!

washer.jpg

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You got the complete repair manual? take a good look maybe you can spot it on one of the diagrams? Or on the parts list, it should be listed somewhere in there? Good luck

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Order that part from Honda and see if it is the same . I guess is that is the part . 

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Thanks guys.  I am going to order the part.

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Yes #11, if any body has their XR400 apart please take a photo and post.  I also put this message on Thumpertalk.  I have ordered the washer anyway.

 

 

washer2.jpg

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What a sinking feeling to be finishing something up and then find an extra part laying around.  That shouldn't be too hard to get to.  

 

Whenever I have extra parts I just figure that it's weight savings and consider it an improvement on the original design.

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1 hour ago, tntmo said:

What a sinking feeling to be finishing something up and then find an extra part laying around.  That shouldn't be too hard to get to.  

 

Whenever I have extra parts I just figure that it's weight savings and consider it an improvement on the original design.

Hopefully just a right side case removal and possibly clutch removal.

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Update:  THIS IS NOT THE RIGHT WASHER.  I dove back in the right side.  (I could not wait for that washer to arrive in the mail). This is a thin washer, not a thick one.

washer2.jpg

 

drum.jpg

 

On the two diagrams above, #11 and #14 are the same part number.  So, I went back in and looked at #14, which I could do from the side cover without removing the clutch.  It is a flat washer, therefore both #11 and #14 are not the right ones.  They are common thin washers.

Back to square one.  I am starting to think this is just some random spacer that fell off a part.  I will continue to search the parts diagrams.  Thanks all.

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I recently had a similar issue. I took the part into All American and showed it to the mechanic. He knew what it was immediately. So maybe a trip over to the dealership will help you.

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It looks like a spacer they press into some type of plastic part -- side covers --Fender-- ???? 

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2 hours ago, kato said:

Copenhagen!! ?

Off road Denmark!!!

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Must be a Honda thing, I rebuilt a XR650R and it started in two kicks as well.  

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On 7/10/2017 at 5:51 AM, tntmo said:

Must be a Honda thing, I rebuilt a XR650R and it started in two kicks as well.  

Was it the mechanic or the bike? 

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7 hours ago, Reximus said:

Was it the mechanic or the bike? 

It was the guy who kick started it.

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