Update.
Everything put back together. New oil, clutch adjustment etc.......no change. Still the same noise and no gears.
Engine runs fine. Its when I stick it in gear and release the clutch I get a grinding noise and no bite. This is through all the gears. Same noise and no bite from the clutch. I could sit on the bike with the clutch out, in gear and it won't move.
Any ideas? I can see this being expensive

 

You're going to have to probably pull the clutch pack, and check the transmission shafts, sounds like the transmission may have to come out too. Luckily, on a 1994 it's not a horribly difficult job. Have you checked your belt pulley to see if it stripped the splines where it goes to the transmission output shaft?

John

 

I have heard that could be the issue. Apparently you need specialist tools for the job. Is it a simple task to I expose the belt pulley? I am tempted to pay somebody else but would like to see if I could do it first

 

Might have to remove exhaust pipes, then remove sprocket cover so you can take a look. That's not too difficult. Be sure to soak your exhaust studs in some penetrating oil for a day or so and then take the nuts off gently.

John

 

I think I may have found the problem.
Stripped the exhaust off and got in to the transmission pulley area. Removed the retaining plate and it is completely rounded off.
I need advice on how to remove the shaft nut. I know it's a left hand thread but I don't have a fitting big enough to remove it.
Any ideas?

 

Guys I'm pulling my hair out. I have just had a go at removing the front pulley and the whole shaft just spins. I tried putting it in gear. Still spins. I can see the primary chain jumping slightly when I try and turn it. I'm slowly finding the root of the problem but I am not sure I am at the right skill level to give it a go.

 

Can you post up some pictures? What retaining plate is "rounded off?"

Is your belt still on the pulley? How about someone holding the wheel and belt tightly? I realize you may have the master cylinder off, so using rear brake to lock the wheel may not be an option. Tie the spokes to the swingarm to lock it? Piece of wood across swingarm forks, through spoke, assuming you have cast wheels, of course. That sprocket has to come off if you do need to pull the transmission, but maybe not. If it ends up being a bigger job than you can do, at least you identified the problem. That's important in itself. You won't look stupid, or get ripped off.

Hopefully, a more experienced member can help out.

John

 

Thanks john.
The issue I'm having is that the nut is spinning inside the front pulley. So looking the rear wheel up or holding the belt is not going to work. The nut. / Shaft still spins.
I will get some pics up later today.

 

Well, it does sound like the pulley stripped. Can you have someone put a wrench on the clutch hub nut and hold it?

John

 

Sorry, haven't been on this thread for a while. If you haven't made any more progress, here's a way to lock that transmission shaft from turning. It requires taking off the primary cover, though.

This tool works, and it's about the cheapest:

Here are a bunch of photos, some that show how that tool is used.

I'd like to know what you'd find, and I'll check back here to see how it's going.