Haven't taken a look yet as I am doing fork seals at the moment but bikes starts and runs fine in neutral. When I pull the clutch in I get a horrible 'grunching' noise, sounds like a clapped bearing? Is this a big job, small job or could it be a number of different things? Do all my own spannering so I will dive in and do whatever it takes. Thanks for any comments.
It's not too big a job,you will need a clutch holding tool if you remove the outer basket.
It could be worn plates or the plates "ears/tangs" are sticking in the grooves they make in the inner and outer baskets.
These grooves can be filed down to make their action smoother and it takes some time doing this.
There is a flat needle roller thrust bearing on the grooved rod which is behind the pressure plate that may need looking at but is usually ok.
Replace the engine oil when you reassemble it with a good quality brand oil specific for 2 stroke gearboxes such as Silkolene LIGHT GEAR OIL,other brands available as this topic has been covered recently on this forum.
Thanks for the response.
As soon as I've done the forks (I've just ordered a set of long allen key 1/2" drive sockets. Not the best make in the world but I guess I won't need them too often) I will go clutch noise hunting. All my usual tools are Sears Craftsman from the US - I used to go there every month, empty case out, full weight case back!
Nice to see another 1KT local to me, Good luck sorting your clutch issue.