Didn't necessarily mean WEAR marks. I couldn't edit the title after submitting it.
Just noticed these marks on the edges of each steel washer. At first glance I saw the rear washer and thought it was digging into the softer hub material, but the front washer (steel over steel) has the same marks. So apparently those rough edges are the washers themselves.
No way the rear washer could be forced over the front washer and cause the marks. The nut is supposed to be torqued to 101 ft/lb from the factory. I don't think a socket could cause this while the nut was being torqued. I've never touched it.
It looks like the back edge of each washer is being pushed or rolling up on itself?
I've never bought any kind of washer that had edges like that either.
What could cause these marks?

* Last updated by: KAK on 12/15/2012 @ 3:10 PM *

Well now...that IS interesting.I can only think...maybe...when they made those washers they somehow missed the deburring process or something.I can't imagine the heat and force it would take to shear that surface up and over the flange like that....IDK what to say.It's so minimal...even if it was 'extra' on the flat of those washers...I can't see that having an effect.That nut on there...it can't just arbitrarily tighten itself up...especially past the tightest it can go(torqued).That's just....odd.Does it look like it's being forced up and out around those washers?It looks like that from here.Can't be...can it?

It's supposed to have...2 washers right there?I don't remember mine having two.?????I don't have my 07 service manual....that's very strange.

Did you get that nut off of there?If not..you might just want to now...to see what's happening behind that inboard washer.I can only think that from what it looks like to me...that basket is somehow spinning?Can that happen?That isn't normal..that washer material.It may be nothing...but that nut....the lower threaded surface right there at the tip...it looks like it's got the same 'stuff' in there...but not coming out...could just be how it was machined...but....

* Last updated by: Grn14 on 12/15/2012 @ 7:04 PM *

I think the nut threads are just rough cast...they don't polish most parts to a perfect shine. I think the "rolled out bur along the edge of the washers is also lack of perfect finishing or perhaps some sort of crush material that is meant to keep the nuts from coming loose. I don't see how anything could be waring there from under the washers.

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That's just some flashing from when the washers were stamped out of sheet metal. It becomes more pronounced as the punch and die wear. Nothing to worry about.

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There are two washers on there...no worries.

I was looking at my service manual to see what your looking at but totally different for the "slipper" on the 2012.
But if I remember from my 08, the outer washer has an outside mark shown in the manual. From your picture, inside the basket, I see some scratch marks on one of the spines that the spring bolts go's into from either you or if somebody else has been inside the clutch. Just wondering if you can see this outside mark on the outer washer that I feel I remember from the manual on my old bike? Maybe just backwards although I don't believe this would cause your problem either.

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I appreciate the help.

It's supposed to have...2 washers right there?I don't remember mine having two.?????I don't have my 07 service manual....that's very strange.

Grn:Two washers is correct for the '07. And the front washer has a raised circular ridge that the nut either fits around or fits into. I haven't taken off the nut because I don't think I need to inspect further. The replies I've got today verifies I don't need to remove the nut and check out those spacers.

But if I remember from my 08, the outer washer has an outside mark shown in the manual. From your picture, inside the basket, I see some scratch marks on one of the spines that the spring bolts go's into from either you or if somebody else has been inside the clutch. Just wondering if you can see this outside mark on the outer washer that I feel I remember from the manual on my old bike? Maybe just backwards although I don't believe this would cause your problem either.

AV8ER:I lightly sanded away those scratch marks in a couple places as you mentioned. I doubt they were causing trouble but I figured smooth is better and I went around the entire hub and basket.
Yes, the outer washer has the words "OUT SIDE" on it and mine's installed correct. There's a circular raised ridge on one side that I'm guessing fits into the nut or the nut fits over it.

That's just some flashing from when the washers were stamped out of sheet metal. It becomes more pronounced as the punch and die wear. Nothing to worry about.

hagrid: You sound like a man that knows all about this. I appreciate the reply. Takes a load off my mind.

I think the nut threads are just rough cast...they don't polish most parts to a perfect shine. I think the "rolled out bur along the edge of the washers is also lack of perfect finishing or perhaps some sort of crush material that is meant to keep the nuts from coming loose. I don't see how anything could be waring there from under the washers.

Rook:Thanks. I've bought lots of washers over the years and I never noticed something like this, so it had me scratching my head.

I'm going to have to agree with hagrid on this one.
If you look at just about any steel flat washer, like a Penny, it has 2 sides. Like heads and tails. On one side, the edge will be smooth and rounded over. On the other side, there's usually a sharper edge that's rougher, with a bur.

ErikR:Thanks. Just another good way to make sense of this.
Also, I agree my problem is probably hydraulic related. If my problem is still there then I'll probably rebuild the slave next. About $80 shipped for the 5 parts I need. After that I'd have to look at replacing the MC but it sure seems to be operating like it should.
The bike was new when I bought it and it just started doing it before I touched anything. I baby the bike so I'm surprised I have this going on. It's easy enough to live with but it bugs me at times so this is my second attempt to find the problem. It would probably bother someone who liked to race a lot because if you were shifting quickly the sudden extra play that appears could throw off your hand and foot timing a little.
I appreciate ALL the help. Since I saw those washers yesterday I've been stressing over what could cause that. One of the first possibilities I crossed off was rough finishing. So then I was thinking damage. I never really thought a washer that goes inside an engine could have such a rough finish allowed. The "burrs" seem to be on the washers solid so I'm not going to mess with 'em and see if they chip off. If I had a holder tool for the hub I might remove the nut and washers and clean them up but I don't so...

* Last updated by: KAK on 12/16/2012 @ 12:49 PM *