Bolted the whole thing back together today, Replaced and bled fluids.
And tried the big test of firing her up - healthy spark but no joy so I decided
to try and bump start it, which is when I realised that no matter what gear I
put the bike in it doesent turn the piston - although there is a noticable drag
at the back wheel as appose to neautral posistion, like the cluth is partially
engaged? any ideas on what I have fucked up with? The plates went back in the same order
as was taken out.....I'm at a loss. only other thing I can add that is unusual is when kicking
the engine feels to have slightly more compression than usual - only a bit.

I should add that I've slackened the clutch cable right off too, just incase it was that.

Have you got lots of oil on the friction plates?

There seemed to be a fair amount I left them to soak for a while wihile they were cable tied together as
a bundle. They were'nt dripping when I put them back but were definitly coated.

In essence, the drive plates are being held slightly away from the driven plates at what should be normal operating conditions? possible causes could include,
?is the clutch actuating arm fully bottomed out into its housing, this allows the actuating shaft to align with the indent on the base of the shaft.
are you positive about correct assembly of thrust washer arrangement?
you have torqued down the clutch springs fully havn,t you ?
worst case, the drive is not being transferred between input and output shafts due to incorrect reassembly of gearbox components

Is this petruding too far out?

When you pull the clutch lever in does it feel like it's working proper like?

Yeah, it feels absolutley perfect

Probably more like the gearbox then!
Have you had it completely apart?

Well it has been apart, but since I was having problems splitting the crancase I got a Honda dealer
here in Leeds to split the case and fit some main bearings and they bolted the crank together again.

when I was fitting the gear selector I checked that the front sprocket did move whilst in gear
when I turned the crank - which it did in all gears but neutral.

And it doesn't now with the clutch connected?
Can you see if the plates are separating?

I can't tell at the moment as the case is bolted on, but after I looked at it before I bolted the clutch side case on and seemed to be functioning - as in - it was moving outwards when I engaged the clutch

How much free play is there on the end of actuating arm in casing[ where cable attaches].there should be a few degrees of movement.
Sorry mate ,your going to have to take casing of again to check clutch reassembly.

I don't think there is any free play in the arm- fitting the clutch cable was pretty diffificult
and a hell of a stretch to the acutator arm, If it does turn out to be the acutator arm, what do you think
needs rectifying? does the push rod only install one way round? I can't think what to do differently
when I strip it again tommorrow.

my first look would be at the push rod / release bearing arrangement, as their should be a bit of movement on the actuator arm,and i would suggest that maybe the push rod is not in contact with the flat face at the bottom of said arm,or the bearing /washers are incorrectly reassembled leading to the plates not being able to mate fully together.