Yes roller plate has got a "lip"

So u think the starter gear and key will be ok?
I ll only need a new fixed drive face the washer behind it and the roller plate?

thanx for ur help!

 

You have a long spacer. Short spacer measures 1.275. NO washer is needed for you.
It seems that it came loose for another reason other than no washer..Make sure the washer under the nut is a spring washer.
No matter, let's get this one put together correct.
The pic shows me that you have not removed the cover to clean and inspect the variator and rollers.
FYI: there is a guy on ebay that sells the whole front clutch.
Seeins you need the fixxed face (the fixxed face spins on the crankshaft splines)(and unknown damage inside), and roller plate, that complete kit may be a good deal for you.
http://www.ebay.com/itm/SUZUKI-LT80-KFX80-COMPLETE-FRONT-DRIVE-CLUTCH-87-06-/400257501089?pt=Motors_ATV_Parts_Accessories&hash=item5d3134c7a1&vxp=mtr

 

long spacer for sure!
Suzuki parts list catalogue mentions that the spacer is 1.273 long and the washer 0.118 inches.
Mine is 1.38 total so that should be almost correct. No need to install a washer then.

I cant figure out why the starter gear and the roller plate were rubbing together so i can prevent this from happening again
So u saying i should only buy the complete front clutch kit and no starter gear

 

I 've changed the rollers recently with new ones. There isnt any damage inside the variator.
Nut was loose when i removed the engine cover to inspect whats wrong. The washer is not a spring one but its the original washer. I have to replace it with a spring washer?

Also noticed a lil notch on the roller plate. Should the plate's notch slide onto the key and lock there?

 

Seeins we know someone was into the clutchs, It's probable that they lost the spring washer and used another type.......wrong.....
Yes you need the Suzuki washer that goes under the nut and make sure it's on the correct way.
Part number 09164-12020

The starter gear should be fine. Just clean it up a lil with a file.

Yes, the notch in the roller plate needs to be aligned with the key on the crank. The key only sticks out a little but it works.
"I 've changed the rollers recently with new ones"
Are you saying that you replaced the rollers, ran it, then this happened?


FYI:Once we get this together correctly and the nut impacted on, it should be fine.

 

Had it in a workshop for the service didnt do it alone

Yes replaced rollers with original ones and got a new piston.
Ran it for a total of 5-6 hours then heard the weird sound!

I have that washer 09164-12020 installed but not sure whats the correct way

The key is pretty shaved dont think it will hold the plate.

I m starting to believe that all these happened cause they didnt align correctly the roller plate on the key so plate was spinning and chewed the key and then the starter gear.
Is this a possibility or i m totally wrong on this?!

 

There we have it.
You're correct, key wasn't aligned with the keyway when assembled. Once it ran enough to spin the roller plate to the key, it loosened because of that creating a space and then it only got worse. Not long after, you noticed the trouble.
The key is hard. Surely you can get a new key but the old one should work with a lil filing/sanding to clean the edges up.
The key is for alignment mostly. It has minimal side pressure. It's when it's all bolted together tightly that holds everything in place.

Lay the spring washer on a flat surface. It won't lie flat. It'll either be dome up or dome down.
You install the washer dome out so the nut pushes down on it making it like a lock washer.