Rotor

[zed1015]

Ok!
The clutch locking up issue is mainly down to the thrust washer/s as the damper only sits on the gear .
Now that you have the rotor problem cured you need to find some end float clearance for the starter gear.
I would remove the damper and thrust washer and measure how much end float you have with feeler gauges or such like.
That thrust washer is pretty thick so i doubt there will no float with it removed.
You need to reduce the thrust washer thickness to slightly less than the end float measurement, then the starter gear won't get nipped tight when the rotor is torqued up.
Just flat the washer on fine wet'n'dry.
Once that is done the damper issue can be solved in the same way if the thinnest damper is still too thick.
The damper only needs to give slight drag when rotating the starter gear clockwise.
If you were closer i would sort this for you.

[mikey]

Cheers Rob ill have another look at it all tonight

[mikey]

Gotta laugh cant get the rotor un done now
and all this started cuz it kept coming loose

[hillbilly]

take your time mikey.

[coldsummer]

Gotta laugh cant get the rotor un done now
and all this started cuz it kept coming loose