[AlabamaKC]

The engine was stuck let wd40 sit in there over night. I freed it up. Got some power going to it, even straight to the starter, the solenoid fried I think. But can't get it to try to start, need to check for fire now. I took the side housing off where the shifter was. I ended up pulling the shift rod from inside the engine completely out because it was stuck to the housing cover. did all the clutches fall down into the engine? I can't get it to change gears to make the neutral light come on. It was on when I started messing with it. It's been sitting 7 years.

 

[shadetree]

welcome. sooooooooooo..you pretty much tore into it going blind then...right ?. down load the service manual, start reading it. trust me, your in deeper than you thought when it comes to just pulling things apart, and not know what your doing . from the sounds of it, you will need a total top end rebuild, and a few other things.

 

[SamUK]

Welcome to the forums.
These are great little ATV’s and just like 300’s one of the best to start learning on as they are quite a basic machine. As shadtree said, if the top end was seized it’s sounding like a top end rebuild is in order.

The factory service manual is available in the sub section ‘manuals & schematics’. I’m pretty sure the shiftblever is held in place with a circlip so that’s another issue you need to sort out, you don’t want that floating around inside the engine.

 

[shadetree]

Welcome to the forums.
These are great little ATV’s and just like 300’s one of the best to start learning on as they are quite a basic machine. As shadtree said, if the top end was seized it’s sounding like a top end rebuild is in order.

The factory service manual is available in the sub section ‘manuals & schematics’. I’m pretty sure the shiftblever is held in place with a circlip so that’s another issue you need to sort out, you don’t want that floating around inside the engine.

nope, the shifter shaft slides out just like they do on the trx300's. the problem he has ?, now that he pulled the shaft all the way out when he yanked the left cover, is now the clutch arm on the right side is just sitting there, and no way to line it all up without pulling right side cover ?, there goes another gasket that will need to be replaced.

 

[shadetree]

OP, what ever you do ?...DO NOT TRY TURNING THAT MOTOR OVER !!!. why ?, simple : if it sat that long, and motor was seized ( or in your case..it was ! )..then this mean the rings were rusted to the cylinder, and when this happens ?.. and you go to spin it over ?, its like dropping 50 grit sand paper down in the cylinder !. this mean...if it wasn't ruined before you spun it ?, then it sure is now !. sorry for saying it like it is ?, but..well..it is like this, you learn this stuff when you do it for 25 plus years .

 

[cmanningjr]

Welcome to the forums.
These are great little ATV’s and just like 300’s one of the best to start learning on as they are quite a basic machine. As shadtree said, if the top end was seized it’s sounding like a top end rebuild is in order.

The factory service manual is available in the sub section ‘manuals & schematics’. I’m pretty sure the shiftblever is held in place with a circlip so that’s another issue you need to sort out, you don’t want that floating around inside the engine.

nope, the shifter shaft slides out just like they do on the trx300's. the problem he has ?, now that he pulled the shaft all the way out when he yanked the left cover, is now the clutch arm on the right side is just sitting there, and no way to line it all up without pulling right side cover ?, there goes another gasket that will need to be replaced.

Been there, done that.. lol sucks


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[shadetree]

Welcome to the forums.
These are great little ATV’s and just like 300’s one of the best to start learning on as they are quite a basic machine. As shadtree said, if the top end was seized it’s sounding like a top end rebuild is in order.

The factory service manual is available in the sub section ‘manuals & schematics’. I’m pretty sure the shiftblever is held in place with a circlip so that’s another issue you need to sort out, you don’t want that floating around inside the engine.

nope, the shifter shaft slides out just like they do on the trx300's. the problem he has ?, now that he pulled the shaft all the way out when he yanked the left cover, is now the clutch arm on the right side is just sitting there, and no way to line it all up without pulling right side cover ?, there goes another gasket that will need to be replaced.

Been there, done that.. lol sucks


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yep..been there, done that as well !. I learned the hard way, just as he will, don't go yanking stuff unless you very well know what your getting into !..lol. i'm surprised he hasn't yanked the output shaft out the left side yet ?, lord help him if he does that !!..lol.

 

[cmanningjr]

We all got to learn sometime.. lol

He’ll be fine if he gets a service manual and comes back here..


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