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Discussion Starter · #1 ·
Newbie here,
Have a 93 TRX 300, that started with a starter problem pulled the left side plate off the motor and rebuilt the starter now it, starts like a champ, runs fine, drove it around the yard for about 2-3 mins, up shifted fine down shifted fine, then i down shifted and it came to a stop and nothing happens. The motor runs fine, and i can move the shifter up and down but the atv wont move. What could be the problem and how would one fix it?
I had this posted in the trx section and got a few replies there but thought i would post here to see if i could get some more hits. Thanks so far for the help...
Tracy
 

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if i'm not mistaken..the gear shift is on the side that you took off, if this is the case, then you will need to take it back off, and look at the shifting arm and such..sounds like it's not making a full turn on the gear notch spacing..there is a star looking wheel with about 4 or 5 notches in it.and the shifting arm has a small wheel that rides in each notch when you shift it..from what your saying..it seems to be hanging in between these notches, your going to have to take it back apart..and check this out.
 

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Yeah, I agree with Shadetree. I would take it back apart and look for something wrong or out of place there.
 

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Discussion Starter · #4 ·
OK, so now i checked the star wheel thing, every thing seams to work well, made one small adjustment, and now it seams ok, i can move up and down through the gears just fine, except it still wont move, I can put it in gear and still move the back wheels, and also to add a extra degree of dificulty the kick start doesnt seam to engage the motor. My guess is the splines on the end of the shaft opposite the end with the shift handle arent lined up right but i have no idea how to get them lined up. Thoughts??
 

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OK, so now i checked the star wheel thing, every thing seams to work well, made one small adjustment, and now it seams ok, i can move up and down through the gears just fine, except it still wont move, I can put it in gear and still move the back wheels, and also to add a extra degree of dificulty the kick start doesnt seam to engage the motor. My guess is the splines on the end of the shaft opposite the end with the shift handle arent lined up right but i have no idea how to get them lined up. Thoughts??
If you look close, there should be an index mark on the inside of the crankcase and a punch mark on the piece that slips off the splines, that has to be lined up. Let me see if I can find a picture.
 

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Is this what you are talking about?

 

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OK, so now i checked the star wheel thing, every thing seams to work well, made one small adjustment, and now it seams ok, i can move up and down through the gears just fine, except it still wont move, I can put it in gear and still move the back wheels, and also to add a extra degree of dificulty the kick start doesnt seam to engage the motor. My guess is the splines on the end of the shaft opposite the end with the shift handle arent lined up right but i have no idea how to get them lined up. Thoughts??
If the kicker won't turn the engine over, the one-way clutch bearing is out. It is on the inside of the centrifugal clutch. They usually start going bad and the kicker will just catch sometimes and it will keep getting worse until finally it won't catch at all. Also, when going downhill or coasting, the engine won't hold the 4-wheeler back. It will act like it just goes into neutral. When it does this, just bump the throttle and it will start holding back again.
 

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Discussion Starter · #8 ·
Thanks Helmut, the pic that you have is that of the left side of the motor with the shifter on it or the right side with the kickstarter?
If its the right side, what will I have to watch for when i take that side off? Thanks again so much....

for the kick start, will that bearing be something i can fix or will it be a shop job?
Im very green at this but we have 4 of these models that I would love to be able to work on so thats why i ask Thanks Tracy
 

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Thanks Helmut, the pic that you have is that of the left side of the motor with the shifter on it or the right side with the kickstarter?
If its the right side, what will I have to watch for when i take that side off? Thanks again so much....

for the kick start, will that bearing be something i can fix or will it be a shop job?
Im very green at this but we have 4 of these models that I would love to be able to work on so thats why i ask Thanks Tracy
That picture is the kick starter side. That part in the picture, that you have to align, fits on splines on the other end of the shift shaft. If you pull the shift shaft out from the shifter side of the engine, it will disengage the other end from the splined part. That part is what engages and disengages your clutches, when you shift gears. Has anyone had that side cover off before? That could have been what happened if someone has had either side cover off.

Things to watch for when taking the clutch side cover off are: (1) the kick starter shaft will try to pop out, (2) the shaft that the reverse lock out lever bolts to will pop out, (3) the other parts that the internal clutch lever (the part in the picture) engage will fall out of place (that picture does not show all the other parts). By the way, if that kick starter shaft pops out, and it probably will as it usually does, if it's not put back in right it will damage the gears on it.

For the one-way clutch bearing(this is the piece that's causing your kicker to not turn the engine), once you get the clutch side cover off (kick starter side), you will see the centrifugal clutch on the end of the crankshaft. You have to remove the centrifugal clutch as the one-way clutch bearing is on the inside of the centrifugal clutch. There is a big nut that holds the clutch on. It has left-handed threads. After you get the nut off, the clutch may or may not pull off. Sometimes you have to have a puller to get it off. It takes a special puller. A lot of times you can take a hammer and tap the side of it, just enough to jar it, and then take both hands and pull real hard and it will come off. If it don't you will have to have the puller. When you get it off, pull the inside of the clutch out of the shell, being careful that you don't drop the one-way bearing out. Watch how it comes out, because it will only work right one way. It will fit either way, but it won't work right when you get it back together unless it's in right. They usually have an arrow on them, so look at which way the arrow is pointing when the old one comes out. Assembly is just the opposite of disassembly.

If you've never worked on these before, it might be difficult for you, depending on your mechanical ability. But if you think you can do it, it would be a good ideal to get a repair manual. Good luck.
 

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Discussion Starter · #10 ·
THANK YOU THANK YOU THANK YOU
took that side plate off, held everything in place, lined up the mark on case and the other mark, put her all back to gather, fresh oil, drove around the yard, up shifts like crazy, down shifts like crazy runs just great, no noises or anything. Thanks again helmut for all your help and patience, this is one newbie that will be doing more fixes.... thanks again Tracy
 

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THANK YOU THANK YOU THANK YOU
took that side plate off, held everything in place, lined up the mark on case and the other mark, put her all back to gather, fresh oil, drove around the yard, up shifts like crazy, down shifts like crazy runs just great, no noises or anything. Thanks again helmut for all your help and patience, this is one newbie that will be doing more fixes.... thanks again Tracy
Your welcome. Glad you got it fixed.
 
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