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Discussion Starter #1
Hey all, a few months back i acquired a 1998 trx 300 'parts bike'. It was in too good of a shape to use for parts so decided to get it running after sitting for a good few years. After test riding i soon discovered some problems, top end rebuild was needed and shifting was quite rough. After doing the top end and putting afew hours on the bike, shifting is still rough.

So the problem is their is no neutral in between gears, the shifter fully up or down in gear does nothing to hold the bike back. Clutch adjustment has no effect, and it seems to jump into gear, more so downshifting than upshifting but still doesnt 'flow' into gear like it should.

So my question is what side cover am I pulling off? And should i still be driving it? Ideally I'd like to put another 10 hours on it to change the oil and while oil is drained pull a side cover off to see what may be wrong.

Thank you all, any help would be appreciated.
 

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Quote" So my question is what side cover am I pulling off? And should i still be driving it? " Quote

The right side cover is where the clutches are , I wouldn't ride it till you fix it , the clutch material could be deteriorating and going into your oil and flowing thru your engine ------ you say the bike has been sitting up for a awhile , maybe the clutch plates are stuck together
 

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Discussion Starter #3
So are the clutch plates ment to move loosely? Im assuming the centrifugal clutch is worn? Still good, or is repair required? And is the filter screen and the junk underneath the only thing i have to clean? Or is it too late?

Sorry for all the questions but I'm really curious.
 

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So are the clutch plates ment to move loosely? Im assuming the centrifugal clutch is worn? Still good, or is repair required? And is the filter screen and the junk underneath the only thing i have to clean? Or is it too late?

Sorry for all the questions but I'm really curious.
hard to tell ?, but it looks either like leaves ?, or friction disk under your pick up screen. friction disk are loose to a point on all of them. no way of telling if the centrifugal clutch arms are worn out of spec without removing them, and mic'ing them :).
 

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Yep, that is quite a collection of junk under the screen. There is probably more in the bottom of the crankcase... The cases should be split for cleaning and inspection and to replace anything that needs replacing.

The centrifugal clutch looks OK in the photo, but photos don't show detail, so not much help. The service manual shows how to check those for wear, its pretty simple too.

The change clutch pack is probably stuck. Take that apart and carefully separate the friction discs from the steel discs. Clean the frictions in a light solvent and measure the thickness of each as the service manual says... look for any warped or damaged steels and if all is well, dip the individual clutch discs in clean motor oil (JASO MA or JASO MA2 certified) until they've soaked up oil and install them... follow the manual closely... and let us know how it goes if you can.
 

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Discussion Starter #6
Righto looks like I have a loooong weekend ahead of me.

Thanks everyone I'll report back to either say how I went or to ask more questions lol.
 

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Righto looks like I have a loooong weekend ahead of me.

Thanks everyone I'll report back to either say how I went or to ask more questions lol.
fire away with questions !. your in good hands here !.
 

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Discussion Starter #8
As promised more questions!

Well just one really, how does this 27mm nut come off the centrifigul clutch? I know an impact gun would be ideal, but I dont have access to one yet....
 

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Just a suggestion... While your pulling it apart for what change clutches cost I'd just replace it. It's one possible issue eliminated out of a possible few.
As @retro said above, that crankcase wants a good clean, you can flush with diesel or kerosene, I do this myself from time to time and it does remove any gunk and silt, maybe not all but certainly enough to prevent further damage to internals.
 

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As promised more questions!

Well just one really, how does this 27mm nut come off the centrifigul clutch? I know an impact gun would be ideal, but I dont have access to one yet....
air impact is about the only way your gonna zip the nut off.
 

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Discussion Starter #11
Alright, borrowed an impact from a friend down the road and it zipped the nut right off! Awesome tools aren't they?

So by the looks of things someone may have been in here before, because the nut was not staked and i couldn't find a washer behind it....

But the main problem is that this clutch is in their tight! Tapping on the outside seems to want to move the primary gear out instead of just the clutch. There shouldnt be any more nuts holding it on? Just the 27mm left hand thread on the front?

Any tips to get the clutch off, or do i have to find a puller?
 

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Alright, borrowed an impact from a friend down the road and it zipped the nut right off! Awesome tools aren't they?

So by the looks of things someone may have been in here before, because the nut was not staked and i couldn't find a washer behind it....

But the main problem is that this clutch is in their tight! Tapping on the outside seems to want to move the primary gear out instead of just the clutch. There shouldnt be any more nuts holding it on? Just the 27mm left hand thread on the front?

Any tips to get the clutch off, or do i have to find a puller?
should be a washer behind the staked nut !. spec clutch tool to pop the clutch off, or use a hammer, rubber mallet, and smack it off, ive done it both ways.
 

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Discussion Starter #13
Would shot clutch disc and plates cause this? Pulled it apart yesterday (I'm losing count now lol...) and had a second look at the disc and noticed one was slightly concaved....I suppose this could be my problem?..the clutch centre (going off names in the manual) not seating all the way down, leaving the clutch plates and disc loose? New disc, plates, springs and all should be good? Oh yeah, so much for a weekend project lol...
 

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Yeah, those clutch discs should be flat. My guess is that someone had it apart before and pinched the disc when putting it back together. A new clutch disc set and replacement of any missing or worn out parts will probably fix it.
 

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Discussion Starter #17
So recently my 1993 300 started doing the same thing, slowly got harder to downshift and clutch adjustment started having no effect. Then went to adjust clutch and then nothing, but lurching straight into gear. Pulled clutch cover and found timing chain was stretched beyond limit, but clutches seemed to be in good order.

So while my 93 model is off the road I swapped the disc and plates over to my 98, put it back together and the same cursed lurch into gear.

Both bikes are doing it now, any idea on how to get the main clutch to do its job again? Or what the problem may be?

Any help is greatly appreciated!
 

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I would say you got your clutch adjustment all wrong.
 

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Discussion Starter #20
Im almost positive that i got the disc as far down as possible...ShadeTree what do you mean about the clutch adjustment?
 
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