[Kwahaes]

I am new to the forum and so far, it has been very helpful. It is time to put it to the test though....

I recently purchased a 98 TRX300EX. At times it will start no problem. Other times, it will just click. When the clicking occurs, if I let out the clutch while it is in gear, rock the ATV back and forth in gear, then pull the clutch and it will start. Any ideas what this might be? Solenoid? Starter? or something else?

Any help would be greatly appreciated.

Thanks,
Frank

 

[jcupp83]

get a multimeter and check to see when the four wheeler clicks if the starter has power to it if it does not have power to the starter check your grounds and check the solenoid . if you starter has power to it i would say the starter has a flat spot on it or it needs cleaned let me know if you need info on how to test the solenoid also make sure your batter is charged

 

[Kwahaes]

Thanks for the quick response. I am sure the battery is good, as I just took it off a charger. I will check the starter for power, but I am suspecting that there is something in the starter that is not engaging. The fact that when I have it in gear, rock it back and forth, then pull the clutch in and it tries to start, seems to indicate something is getting turned in the starter during the rocking of it which then lets it start up. Without rocking it, it just clicks each time you hit the button, but nothing turns over. At times, it will just start right up, but others, I have to have it in gear, rock it, and try again.

I think I have to replace my clutch too. It seems to creep a bit while the clutch is pulled in. I have tried adjusting from the case and at the handle bar to no avail. Although, I won't say I know exactly what I am doing. I have gone back and forth, from nearly no free play at the lever to a bunch and everywhere in between, and the creeping still happens. I have also noticed it slipping when getting on the throttle while riding in just about any gear. I am a bit nervous about replacing this clutch though. Just got off the phone with the dealer in town, they want over $300 to replace it. I can get the kit for a fraction of that. He mentioned having to replace the lock nut because of the stake on it. Do I really need to replace that too?

 

[shadetree]

your starter brushes are bad...when you have it in gear..and your rocking it..it's posb this makes the starter move just enough to make your starter brushes make contact with the armature..inspect your starter brushes.

 

[shadetree]

Thanks for the quick response. I am sure the battery is good, as I just took it off a charger. I will check the starter for power, but I am suspecting that there is something in the starter that is not engaging. The fact that when I have it in gear, rock it back and forth, then pull the clutch in and it tries to start, seems to indicate something is getting turned in the starter during the rocking of it which then lets it start up. Without rocking it, it just clicks each time you hit the button, but nothing turns over. At times, it will just start right up, but others, I have to have it in gear, rock it, and try again.

I think I have to replace my clutch too. It seems to creep a bit while the clutch is pulled in. I have tried adjusting from the case and at the handle bar to no avail. Although, I won't say I know exactly what I am doing. I have gone back and forth, from nearly no free play at the lever to a bunch and everywhere in between, and the creeping still happens. I have also noticed it slipping when getting on the throttle while riding in just about any gear. I am a bit nervous about replacing this clutch though. Just got off the phone with the dealer in town, they want over $300 to replace it. I can get the kit for a fraction of that. He mentioned having to replace the lock nut because of the stake on it. Do I really need to replace that too?

with your bike in gear..loosen the lock nuts down on the case....the upper nut lets the cable give more clutch grab..back this nut off a few turns..then tighten the lower nut. pull the clutch lever in..does the bike move freely ?..if not..go back to the lower lock nuts..loosen the upper nut..then tighten the lower..pull the lever again..keep doing this until you can pull the lever on the handle bars..with the bike in gear..you should be able to move the bike...if none of this works..then yeah..you need to replace your clutch disk. and no..you do not need a new clutch stake nut..just tighten the one you have with a impact wrench..re-stake it back down.

 

[Kwahaes]

Thanks to everyone who responded! I did not get a chance to try anything last night, but I will be sure to give it all a shot this evening. I ordered a new clutch kit from Rocky Mountain ATV just in case. I figured with this being a 98, it probably wouldn't hurt. If it turns out I don't need it, I might down the road so I will just hang on to the kit. I can always return it too I guess, but probably won't do that.

Is replacing the brushes in the starter easy? Where should I look to get those? I don't recall seeing anything like that on Rocky Mountain's website, but I wasn't exactly looking for that.

 

[shadetree]

Thanks to everyone who responded! I did not get a chance to try anything last night, but I will be sure to give it all a shot this evening. I ordered a new clutch kit from Rocky Mountain ATV just in case. I figured with this being a 98, it probably wouldn't hurt. If it turns out I don't need it, I might down the road so I will just hang on to the kit. I can always return it too I guess, but probably won't do that.

Is replacing the brushes in the starter easy? Where should I look to get those? I don't recall seeing anything like that on Rocky Mountain's website, but I wasn't exactly looking for that.

yeah..replacing the starter brushes is easy...before you take it apart..take a nail..or anything with a sharp point..scribe a line across the top and bottom where it joins..so when you put it back together..you can line them up..and know your putting it back together right...look on ebay..or bikebandit.com for your brushes. and while you have it apart..grease up the armature shaft and put alittle on the bearing and washer where it makes contact..don't use alot of grease..just enough to make it turn easier..blow it out with some compressed air while you have it apart..also take some fine sand paper..and clean the armature up where your brushes ride.

 

[Kwahaes]

Thanks again for the info. I was looking at ebay and found starter rebuild kits. Is that even worth it or should I just go for the brushes? I may also have a line on a used starter here in town for less than $20, just need to see if it works first.

 

[shadetree]

Thanks again for the info. I was looking at ebay and found starter rebuild kits. Is that even worth it or should I just go for the brushes? I may also have a line on a used starter here in town for less than $20, just need to see if it works first.

if it's a rebuild kit from ebay..more than likely all it is ..is brushes..and maybe some new shims..other than that..thats all a rebuild kit is. if you can get a working starter for 20 bucks.jump on it !!..just make sure it works.

 

[Helmut]

Thanks again for the info. I was looking at ebay and found starter rebuild kits. Is that even worth it or should I just go for the brushes? I may also have a line on a used starter here in town for less than $20, just need to see if it works first.

if it's a rebuild kit from ebay..more than likely all it is ..is brushes..and maybe some new shims..other than that..thats all a rebuild kit is. if you can get a working starter for 20 bucks.jump on it !!..just make sure it works.

Yeah, the rebuild kits are just the brushes with bushings and o-rings.

 

[Kwahaes]

I will find out this weekend how everything works out. The clutch was delivered to the house today and I just picked up the starter from a local guy who was selling it on ebay. I paid $10 for it! He hooked it up to a battery charger and it seem to work great. Here's hoping!

Thanks for all the help.

 

[shadetree]

your welcome..hope it works for ya !..keep us posted !

 

[jgar]

Thanks for the quick response. I am sure the battery is good, as I just took it off a charger. I will check the starter for power, but I am suspecting that there is something in the starter that is not engaging. The fact that when I have it in gear, rock it back and forth, then pull the clutch in and it tries to start, seems to indicate something is getting turned in the starter during the rocking of it which then lets it start up. Without rocking it, it just clicks each time you hit the button, but nothing turns over. At times, it will just start right up, but others, I have to have it in gear, rock it, and try again.

I think I have to replace my clutch too. It seems to creep a bit while the clutch is pulled in. I have tried adjusting from the case and at the handle bar to no avail. Although, I won't say I know exactly what I am doing. I have gone back and forth, from nearly no free play at the lever to a bunch and everywhere in between, and the creeping still happens. I have also noticed it slipping when getting on the throttle while riding in just about any gear. I am a bit nervous about replacing this clutch though. Just got off the phone with the dealer in town, they want over $300 to replace it. I can get the kit for a fraction of that. He mentioned having to replace the lock nut because of the stake on it. Do I really need to replace that too?

You dont have to replace the nut that is staked. I was able to unstake mine with ease. I used a small chisel and flat head screw driver. Then I backed the nut off with a impact gun, it takes just a quick hit with the gun. Before you tear her down to replace the clutch put it in 5th gear. After removing the crankcase cover put the rear brakes back together. If she is in 5th gear and the rear brakes work it will be easier to remove the staked nut and retorquing (82lbs) it with out the engine wanting to turn AND get a manual!!

 

[Kwahaes]

I forgot about putting the bike in 5th gear, so that is out at this point. I really screwed up big time too. I used the impact wrench to get the bolt off, no problem. Got the clutch all put back together, but had the wrong clutch tool to hold it in place. Tried making the clutch tool I have work and made things much worse. I put the bolt back on with the impact wrench, and then got out my torgue wrench. In trying to hold the thing with my clutch tool and then trying to crank down on the large nut, I broke off one of the pegs to the pressure plate. I have a new pressure plate coming in on Tuesday, so I am hoping to put it all back together Tuesday night. Just have to find another way to keep that thing from turning while I tighten it down.

 

[jgar]

Just put it in 5th gear before you start the assembly. Rock it a little as you go through the gears you will hear them click into place. For this no clutch will be fine.

 

[shadetree]

I forgot about putting the bike in 5th gear, so that is out at this point. I really screwed up big time too. I used the impact wrench to get the bolt off, no problem. Got the clutch all put back together, but had the wrong clutch tool to hold it in place. Tried making the clutch tool I have work and made things much worse. I put the bolt back on with the impact wrench, and then got out my torgue wrench. In trying to hold the thing with my clutch tool and then trying to crank down on the large nut, I broke off one of the pegs to the pressure plate. I have a new pressure plate coming in on Tuesday, so I am hoping to put it all back together Tuesday night. Just have to find another way to keep that thing from turning while I tighten it down.

you don't even need to have it in any gear just to tighten the clutch nut down..just use the impact driver..hit it a few times..and don't worry about it. you can restake the nut if you want..i never do...tighten the pressure plate springs with a socket..take a old screw driver..wedge it between the centrifugal clutch and clutch basket gears..this will keep it from turning..you don't need any kind of clutch holder tool.

 

[Helmut]

I just hold the clutch with my hand and tighten it with an impact wrench. I restake the nut though.

 

[Kwahaes]

That is all great information and much appreciated. I pick up the new pressure plate today after work and hope to get this thing back together by the end of the night.

Thanks again!

 

[Kwahaes]

Just wanted to follow up on all I have done and thank everyone for their help. The starting issue was the starter. I installed the used starter I got for $10 and it no longer does the occassional clicking instead of turning over. Tries to start every time. The clutch is installed and works quite well too. I couldn't have done it without the help and guidance received here. Thanks very much.