I start to fold the tab back with the chisel.  See how nice the tip fits between the tab and the nut.

Then finish up with the punch.  The flat tip on the pin punch doesn't cut into the lock tab.  I can usually use the lock tab over several times, but that's not a good practice.  I suggest you get a new one.  A wrinkled-up washer may throw your torque value off.  Better to use a new washer that is nice and smooth.

Thanks Youz Guys!  

Sorry, the washers I'm referring to aren't those big arse washers I put in there temporarily.  I'm talking about when I removed the nuts from the assembly.  There were no washers.  Clymer says there are washers in there.  I'll look it up on a parts diagram.  If there are indeed supposed to be washers in there under the nut hex, somebody has been in this clutch before me and failed to put them back in.

Yeah, I bought 2 different sized big arse washers.  One pair is good fit; the other pair is not.  I'll get that straightened out.  You're right - the socket can't get in there with those big arse washers.

Can I just pry with screwdriver to straighten out that tab on the locking washer under the hub nut?  I could probably straighten it with a wood chisel too.  I just don't want to scar or tear something up.

Thanks Mike.  Good to know this 2005 S40 has flange bolts and no washers!  This is what happens when you read Clymer word for word!  I’d be completely lost and bum fizzled without your knowledge and help!!

When you say “snag the gear” with your fingers, can you please elaborate?  What the best hand and fingers to get in there?  Do I need to pull the assembly out a bit to get my fingers back there.  My test fingers, with everything still together, seem to think so, or I’m coming at it wrong.

I have a doctor appt this morning and then I want to attempt removal this afternoon.  Thanks.

I have reached frustration level 10.0! in my ignorance!  

I got better-sized temporary washers (I had to go to the hardware store anyway).  I got the lockwasher flattened out without too much anxiety.  The rear brake is locked up.  The rear tire is blocked up nicely with 2x4 secured together.  Bumped up the gear shifter into what I think is 5th gear.

Go to loosen big 32mm nut and the whole motor turns with relative ease.  I can even hear and feel the piston chugging up and down in there.  What the heck?  I go to check the gear shifter --- and it only wants to drop down what I think is 1 gear.  And it's stuck and won't downshift any more.  

I saw Mike's post about jamming a piece of soft copper tubing between the gears, but what's going on?  This thing is loose as a goose.  I don't see or feel any energy trying to move through the belt to the rear wheel.

Should I temporarily put the battery back in and put the gas tank back up there and go back to neutral and try to find 5th gear again?  Maybe I was only able to shift up to 2nd that I thought was fifth and vise versa when I can only seem to downshift 1 gear.  Is it sitting in neutral?

I have no idea where I'm at and what's going on!  I'm stepping away from the bike for now!  I need to chill!  Feeling very concerned and defeated!

Ok.  Took 10 deep breathes.  I'm in neutral and apparently was in neutral trying to turn the nut.  All that clunking, thinking I was bumping up to 5th gear, was fake noise.  

I can bump it down into 1st with a couple tries, but it won't bump up into 2nd and beyond...  This is with a temporary 10mm bolt (bolt thru the frame that was missing and that Mike saw) holding the foot peg, side stand, and gear shifter bracket in place - so it's not totally wonky .

I could keep trying to find 2nd gear...  But, I'm just gunna stop right here and wait for roadside assistance.

Bike is now sitting in neutral with the battery and gas tank put back away on the bench for the day.

Stop!  Take a breath.  Do not attempt to place those fittings in your gear mesh, they are too hard.

I apologize.  I did not recognize just how inexperienced you are.  The question regarding the lock tab washer should have been a clear indicator.  Let's slow it down a bit and see if we can't get you back on track.

If you are in a situation where you can't get on the bike and move it back & forth, you can accomplish the same thing if you jack it up and get the rear wheel off the ground.  Then rotate the rear wheel back and forth by hand.  We're not talkin full rotations of the wheel, just bump it back and forth enough to slightly rotate the trans shafts while you are pulling up on the shifter pedal.