In my opinion the washer should be there. If it won't fit then perhaps you need to find out why?
<I have a washer that looks like it should be between the primary chain crank sprocket and the main bearing>
Is it actually a shim? What is important is that the teeth of the engine sprocket are in line with the teeth of the clutch basket.
<there is a few degrees of play between the sprocket and the crank (I had a broken crank near this point so it was falling apart when I opened it - now has a replacement crank) Is the play normal probably only 2 or 3 degrees (very difficult to measure) but I can't see this tightening up>
No I would not say that is normal. The engine sprocket is usually a fairly tight fit on the crank, usually tight enough to need an extractor to pull it off (that's why the two threaded holes in the sprocket are there). If it's as loose as you say, then I suggest you try another engine sprocket?
<I can't remember if there was an O-ring behind the clutch where the gearchange cross shaft goes through the left hand crankcase. This isn't shown in the parts book either.>
There isn't any O-ring on the cross-shaft behind the clutch.
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