[dxflyer]

Firstly Im new to the forum and not a professional mechanic and maybe I have started a job to big for me, but dont like to be beaten.

Due to a crack in the casing I had to remove the casing on my 300trx that has the gear selector shaft coming out.

I now have the case repaired and have put everyting back together. BUT....

After the job was complete switched the bike on and it was still in neutral, as it was before I started. Tried to go into 1st but it wouldnt go so tried reverse, success there but that is where it my problem starts.

It is now stuck in reverse and I have removed the casing again examined the mechanism to change gear and it looks fine as the selector will move both ways and returns to the middle. However it just doesnt go far enough to hear that magical click of a new gear being selected.

Any ideas what I have done or even better what I might try to do to get the big red back in action.

I didnt take the gear selector shaft right out but it was lifted up as I was removing the casing for the first time, maybe this has caused some of my problems.

Help!!!!!

The quad is a 1996 300 trx

 

[SlammedRanger]

Is it a 300ex or a 300 utility?

 

[Redracer]

Welcome to the family, someone will get you taken care of...

 

[dxflyer]

Ex or utility?

Honestly no idea just says in the handbook trx300. Its not what I would refer to as a racing quad just a very standard machine that is used on the farm here. If it is printed or marked on the bike let me know where and I will find it.

 

[Helmut]

Ex or utility?

Honestly no idea just says in the handbook trx300. Its not what I would refer to as a racing quad just a very standard machine that is used on the farm here. If it is printed or marked on the bike let me know where and I will find it.

Since you referred to it as a Big Red, you are probably talking about the utility with the racks on the front and back.

 

[Helmut]

I didnt take the gear selector shaft right out but it was lifted up as I was removing the casing for the first time, maybe this has caused some of my problems.

If the shifter shaft pulled out some when you removed the cover, then the clutch lever on the other end of the shifter shaft probably came off and then when you pushed the shifter shaft back in went back on, but is probably out of time. The clutch lever fits over the splines on the other end of the shifter shaft and has to be timed or aligned. It has a punch mark on it that has to line up with a mark on the crankcase. The clutch lever is under the clutch cover on the opposite side of the engine.

Make sure that the left side cover is on before you pull the right side cover off. When you pull the right side cover off, be very careful and watch where all the pieces are and some pieces will fall out of place when you do this and you will have to put them back. It's best if the ATV is turned up on it's side when you remove the right side cover. Try to hold the kick starter shaft down so it don't pull up when you remove the right side cover and that will save you a little work when putting it back together as it is tricky to put back in place. The picture below shows the clutch lever and how it is supposed to be aligned. The two red arrows shows where the marks are that has to be aligned and the yellow arrow points to the clutch lever.