What's wrong with my rotor/starter clutch assembly

It took a long time to collect all the parts for my basket case. Now it won't go back together and function. As I tighten down the rotor bolt, the clutch gets stiffer and stiffer until it will no longer free wheel, and the rotor is still not tight enough to not spin on the shaft.
Check out my pics and see if you can see a problem or a part mis-match...this is a '78 kz1000, engine number kzt00ae073545...

Here is the cover I have. I this correct for my engine?

DSCN0274 by seanbarney41 , on Flickr

Here is the the stator and rotor I have. Are these correct? I know there are different stator/rotor combos where the rotor fits around the stator but I don't know what year motors use these. Could the taper on my crank be wrong for this stator?

DSCN0278 by seanbarney41 , on Flickr

DSCN0281 by seanbarney41 , on Flickr

There is evidence that this rotor spun on the crank taper. Could this cause the problem? I am concerned about this ridge that looks worn into the back of the rotor.

DSCN0282 by seanbarney41 , on Flickr

DSCN0287 by seanbarney41 , on Flickr

Here is a virtual disassembly...tell me if I have something wrong

DSCN0277 by seanbarney41 , on Flickr

DSCN0283 by seanbarney41 , on Flickr

continueing to disassemble...this damper washer thing, I realize comes in 3 different thicknesses, mine was the thickest. I initially thought this was the problem, so I sanded down the rubber to slightly less than the thinnest offered. It does not contact the case before the clutch gets locked up.

DSCN0284 by seanbarney41 , on Flickr

DSCN0285 by seanbarney41 , on Flickr

that's about it. Thanks for the help?

DSCN0286 by seanbarney41 , on Flickr

found some discrepancies with the fiche. I have part #5 here

this fiche doesn't have that washer, but has part #23...

is this my problem?

sorry my links don't work. I don't know why. comparing fiches for a2 and b2...I don't even understand why there are so many different options for a '78 kz1000

hi, I'm having the same problem. Member bozo having starter clutch problems as well. Mine didn't come with all the parts if you read his post you'll see what I said maybe those thrust washers don't belong in all of the units I don't know I haven't had a good response with my questions hoping somebody will chime in soon if I find anything out I'll let you know good luck

I looked at my service manual and the cover looks like it is the right one. It also looks like you are missing the idle gear and shaft. Look at page64,65,66,67 on the repair manual. If you don't have a repair manual, I remember downloading a PDF version from somewhere in this site, perhaps someone else can chime in and help you download the manual.

More likely than not someone got in there before and cranked the snot out of it instead of followin torque specs and procedures and wallered out the taper hole in the rotor; or it spun loose once and wallered it out.

Solution; delete the electric start or buy a good condition rotor/clutch; and make sure to install with both surfaces clean and dry, coated with loctite lockin compound and TORQUED properly then you should be okay

mopguy wrote: I looked at my service manual and the cover looks like it is the right one. It also looks like you are missing the idle gear and shaft. Look at page64,65,66,67 on the repair manual. If you don't have a repair manual, I remember downloading a PDF version from somewhere in this site, perhaps someone else can chime in and help you download the manual.

yeah, I got manuals...and I have the idler gear and shaft. I just didn't bother to install them for the pics.

floivanus wrote: More likely than not someone got in there before and cranked the snot out of it instead of followin torque specs and procedures and wallered out the taper hole in the rotor; or it spun loose once and wallered it out.

Solution; delete the electric start or buy a good condition rotor/clutch; and make sure to install with both surfaces clean and dry, coated with loctite lockin compound and TORQUED properly then you should be okay

Floivanus, this is what I think also. Did you see the pic of the back of my rotor a few posts up? Can you tell me if that ridge is supposed to be there?