2003 TRX350TM Shifting Problems - Honda ATV Forum
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post #1 of 22 (permalink) Old 02-21-2017, 05:12 PM Thread Starter
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2003 TRX350TM Shifting Problems

https://youtu.be/psBeQn1VG-U

I need some help with anyone familiar with common issues with hard shifting on a 2003 Honda TRX350TM. I had some issues that progressed from hard shifting to the shifter not springing back to the middle position to the bike not wanting to shift into any gear beyond first. I have the engine out of the ATV and both the front and rear crankcase covers removed. The symptoms and steps I’ve taken are listed below.

•Hard shifting
•Rolling forward while idling in gear
•Attempted to adjust clutch
oFound jam nut seized
oUsed penetrating oil, nut splitter, and impact gun to remove
oCleaned male threads, applied anti-seize, and installed stainless 8 mm nut
•Difficulty shifting into the next gear
•Found shifter was not springing back to middle position
•Could shift if manually moved shifter down after shifting up and shifting up again
•Assumed shifter return spring damaged when overcompensating for hard shifting
•Removed front and rear engine cases
•Front case pushed upwards when fasteners were removed
•No damage found on the return spring
•Shifter began springing back to middle position
•Attempting to shift through gears results in normal N to 1st shift
•1st to 2nd gear shift results in cog getting hung up on point of gear instead of in valley
•Cannot progress to 2nd or make 2nd to 3rd gear shift
•1st to N and N to R found to be normal
•After continuous cycling able to get hung up and go gear point to point instead of valley to valley on 1st to 2nd
•Continuous cycling returns valley to valley shifts but still gets hung going to 2nd
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post #2 of 22 (permalink) Old 02-21-2017, 05:24 PM
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I would say you need to do a full inspection of your shift drum, and all parts connected to it. start at the front, make sure the bolt in the center is tight ?. check the wheel that ratchets in between the star wheel, make sure the wheel and spring is good ?. if that all looks good ?, go to the rear of the engine, have a look inside, and see if the shifting shaft is moving the tang part on the end ?, and its moving the long shifting shaft that comes out the front of the engine to the shifting parts ?. check the end of your shift drum, see if it is snapped off ?, very common for your year model !. if all that checks out good ?, then it's time to split the cases, and get to the shift drum to inspect it, and all 3 shift forks. but I will bet your problem is somewhere in your shifting in the front ?, or back ?, or your not adjusting your clutch correctly ?, the cover should not move upwards at all when you remove all the mounting bolts ?!.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #3 of 22 (permalink) Old 02-21-2017, 05:25 PM
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and welcome to the forums, and down load the service manual from our site here :-).

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #4 of 22 (permalink) Old 02-21-2017, 05:44 PM Thread Starter
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Quote:
Originally Posted by shadetree View Post
and welcome to the forums, and down load the service manual from our site here :-).
I'll have to take another look at it tomorrow. I was trying to refrain from removing the clutch and splitting the crankcase if at all possible as it gets more involved and more expensive to reassemble the further I break it down. I have downloaded the manual and I'm following it as best I can. The reverse stop under the rear cover appears to be working correctly. I will try to use photos/diagrams to explain what I've tried and verify we are talking about the same parts before I progress.

Green 2003 TRX350TM
Red 2003 TRX350FM
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post #5 of 22 (permalink) Old 02-21-2017, 06:23 PM
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Quote:
Originally Posted by lateonthebrakes View Post
Quote:
Originally Posted by shadetree View Post
and welcome to the forums, and down load the service manual from our site here :-).
I'll have to take another look at it tomorrow. I was trying to refrain from removing the clutch and splitting the crankcase if at all possible as it gets more involved and more expensive to reassemble the further I break it down. I have downloaded the manual and I'm following it as best I can. The reverse stop under the rear cover appears to be working correctly. I will try to use photos/diagrams to explain what I've tried and verify we are talking about the same parts before I progress.
you don't need to remove the clutches just to inspect the front area where your shifting parts are :-). but, if nothing is wrong/damaged at the front or back ?, then yes, you will need to pull the clutches in order to get in to the shift drum.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #6 of 22 (permalink) Old 02-22-2017, 06:47 AM Thread Starter
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[/QUOTE]

you don't need to remove the clutches just to inspect the front area where your shifting parts are :-). but, if nothing is wrong/damaged at the front or back ?, then yes, you will need to pull the clutches in order to get in to the shift drum.[/QUOTE]

I don't see any smoking gun. No obviously bent/broken/loose parts. I'll put it up and the bench and start pulling more stuff apart this afternoon. What is the consensus for the best website for buying the OEM Honda parts I need for replacing O-rings and fasteners? I tend to use MotoSport or BikeBandit. Are there any websites that can get the parts significantly cheaper?

Green 2003 TRX350TM
Red 2003 TRX350FM
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post #7 of 22 (permalink) Old 02-22-2017, 10:40 AM
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you don't need to remove the clutches just to inspect the front area where your shifting parts are :-). but, if nothing is wrong/damaged at the front or back ?, then yes, you will need to pull the clutches in order to get in to the shift drum.[/QUOTE]

I don't see any smoking gun. No obviously bent/broken/loose parts. I'll put it up and the bench and start pulling more stuff apart this afternoon. What is the consensus for the best website for buying the OEM Honda parts I need for replacing O-rings and fasteners? I tend to use MotoSport or BikeBandit. Are there any websites that can get the parts significantly cheaper?[/QUOTE]

I was using partzilla for the cheapest parts ?..BUT NOT ANY MORE !..LOL. if your not in a hurry ?, and don't mind being lied to ?, and can wait a month or two ?, use them. or..go to rocky mountain atv, have them price match partzilla, and yes..they will price match !, and you earn bonus bucks for every part you buy !. rocky mountain atv is where you need to buy oem parts from, I know I will be buying from them from now on !.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #8 of 22 (permalink) Old 02-24-2017, 02:05 PM Thread Starter
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I think the front crankcase cover popped off because the adjusting plate and ball retainer were not sitting correctly. The ball bearings were not in the indentation of the adjusting plate, possibly from me going at the frozen nut with an impact gun. I don't see any obvious parts broken and the shift drum doesn't seem to be snapped in the back.

I probably should have asked this up front. Should I be able to shift N to 5th with the engine off the bike? Will this only be possible when the motor/tranny are spinning?
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Green 2003 TRX350TM
Red 2003 TRX350FM

Last edited by lateonthebrakes; 02-24-2017 at 02:10 PM.
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post #9 of 22 (permalink) Old 02-26-2017, 05:03 PM Thread Starter
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I think I've exhausted all I can without cracking the crankcase. I removed the drum stopper in the rear and now I can shift from reverse to neutral but can't go into 1st or higher. Do all the gears use the same shift fork?
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post #10 of 22 (permalink) Old 02-26-2017, 05:05 PM Thread Starter
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More pics and links to video.
https://youtu.be/FF8Q-HqL5k0
https://youtu.be/FSmGqfWukkQ
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Green 2003 TRX350TM
Red 2003 TRX350FM

Last edited by lateonthebrakes; 02-26-2017 at 05:13 PM.
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