[derrick81787]

Hello everyone,

I recently acquired a 1989 Honda TRX300. Overall the ATV is in kind of rough shape, but the engine starts right up with the electric starter and it drives just fine. However, when it starts up I hear a loud clicking coming from the kick start. From what I have read, it sounds like somebody at some point removed the kick start and then reinstalled it wrong. There actually isn't even a pedal on it, but I think that's the only thing missing.

How can I fix this, and do you know what all is involved? I'm kind of a beginner when it comes to working on ATVs, but I'm wanting to learn. I'd prefer to not have to pull the engine or anything like that if not absolutely necessary, though, because I'm not confident that I'd get it back on right. Can I get away with just draining the oil, taking a few bolts off to remove the cover, and getting to the kick start assembly that way?

On an unrelated note, does anyone know where to get a cheap replacement gas tank? I'm seeing them online for $150 which seems crazy to me, but maybe that's just what they run.

Thanks in advance for your help.

 

[SamUK]

Welcome to the forums

If only things were that simple eh! Lol. It is in fact a case of dropping the oil and removing the side case, removal isn’t tricky at all. The tricky bit it installing the case and pieceing together the clutch adjuster.
How would you best describe your mechanical ability? Have you built a top end before or a complete novice?

You can download the service manual from this forum under the sub section ‘schematics and manual help’, in there you’ll find how to remove and install the side case. Maybe have a look before digging into it.

A quick tip if you attempt it.....

After draining the oil jack up the right side of your 300, i found things easier as the side case slid back into place when refitting. It stopped the clutch adjustment shaft dropping down at an angle.

Also, when disassembling, put a white sheet or something similar underneath to catch any parts that may fall as you remove the side case.

Any issues, drop back here and we’ll do our best to help

 

[SamUK]

Welcome to the forums

If only things were that simple eh! Lol. It is in fact a case of dropping the oil and removing the side case, removal isn’t tricky at all. The tricky bit it installing the case and pieceing together the clutch adjuster.
How would you best describe your mechanical ability? Have you built a top end before or a complete novice?

You can download the service manual from this forum under the sub section ‘schematics and manual help’, in there you’ll find how to remove and install the side case. Maybe have a look before digging into it.

A quick tip if you attempt it.....

After draining the oil jack up the right side of your 300, i found things easier as the side case slid back into place when refitting. It stopped the clutch adjustment shaft dropping down at an angle.

Also, when disassembling, put a white sheet or something similar underneath to catch any parts that may fall as you remove the side case.

Any issues, drop back here and we’ll do our best to help

 

[derrick81787]

Hi Sam,

Thanks. This forum seems like a nice place.

I have never done anything like building a top end before. I'd say that I'm mostly a novice to working on ATVs, but I am naturally somewhat mechanically inclined. I have replaced the pull-rope starter on an ATC110 and on a Predator 212 engine that was attached to a go-kart before, and I attempted to replace a one-way bearing for a starter on a 2001 Yamaha Breeze 125. I got the cover off and got to where I needed to take the pulley off just to realize that I needed a special tool that I didn't have, so I settled for cleaning it real good instead of replacing it and fortunately that worked.

I didn't realize that the service manual was available on this forum. I will definitely take a look at that before starting anything. Do you think I will end up needing to replace any gaskets, or is there a decent chance that I can take off the cover and put it back on without messing it up? Obviously that might depend on what it looks like once I get in there, but I didn't know if the gasket is something that always gets replaced when the cover comes off or what.

Thanks again for your help. I will try and read over that manual and maybe I can tackle the job this weekend.

 

[shadetree]

Hi Sam,

Thanks. This forum seems like a nice place.

I have never done anything like building a top end before. I'd say that I'm mostly a novice to working on ATVs, but I am naturally somewhat mechanically inclined. I have replaced the pull-rope starter on an ATC110 and on a Predator 212 engine that was attached to a go-kart before, and I attempted to replace a one-way bearing for a starter on a 2001 Yamaha Breeze 125. I got the cover off and got to where I needed to take the pulley off just to realize that I needed a special tool that I didn't have, so I settled for cleaning it real good instead of replacing it and fortunately that worked.

I didn't realize that the service manual was available on this forum. I will definitely take a look at that before starting anything. Do you think I will end up needing to replace any gaskets, or is there a decent chance that I can take off the cover and put it back on without messing it up? Obviously that might depend on what it looks like once I get in there, but I didn't know if the gasket is something that always gets replaced when the cover comes off or what.

Thanks again for your help. I will try and read over that manual and maybe I can tackle the job this weekend.

first, no need to drain the oil !, iffffffffffffff !!!!!!!!, you tilt the atv on its left side about 45 degree's ?, prop the front and back wheels on some milk crates, 5 gal buckets ?, then pull the cover, and have a look. maybe, maybe not you will need a side cover gasket ??, who knows ?..until you go to remove the cover !..lol. 9 out of 10 times, they never come off in one piece !..lol. there is a oil pick up screen bottom center, pull it, check it, clean it, install back in...BEFORE YOU PUT GASKET ON !..LOL. good luck, keep us posted ! .

 

[fishfiles]

the thing to beware of on that job is : There is a thrush washer on the back end of the kick starter shaft , it can fall off the end of the shaft and go thru a hole into the inner casing and really mess up your day getting it out ------- if you don't realize it falls off while removing the cover , goes in the hole and you run it like that it could cause damage to the "in'nerds"

goin back together isn't as bad , you can put sticky grease on the washer to hold it in place

 

[derrick81787]

I know it's been awhile, but I have finally gotten into it, or at least have started trying. I'm having trouble getting the case cover off though. I unplug the wires, disconnected the oil path pipe, disconnected the reverse switch lever, and remove all of the bolts around the perimeter of the case cover, but it still isn't coming off. I've beat on it with a rubber mallet just to make sure it wasn't stuck, but that doesn't seem to be doing anything.

There is this weird looking bolt in the middle. It's hard to tell from the service manual, but I think maybe I'm supposed to remove it. However, when I turn it counterclockwise to remove it, it just spins forever and never comes off. Do I need to remove it, and if so how do I get it off? See the attached photo for what I mean.

Thanks for the help.

Sent from my Moto E (4) using Tapatalk

 

[shadetree]

whoaaaaaa bro !..that nut is your clutch adjustment !..do not remove it !!. now that you adjusted it all out of whack ?, your gonna need to re-adjust your clutch.

 

[derrick81787]

Oh, great. I have an idea approximately how far I need to adjust it, so I guess I'll get it as close as I can and go from there.

In that case, I think it is time that I just go to town with a rubber mallet. I think I have all the bolts removed, but it just doesn't want to come off.

One last thing that I'm not 100% sure about but think I did right is the switch cover. The manual shows where it is and says to remove it, but I don't see anything I would call a "cover" there. No bolts are left in that general vicinity, though, so I think I have everything. I just wasn't sure.

Sent from my Moto E (4) using Tapatalk

 

[shadetree]

lets back up a bit here . MAKE SURE..AS IN GO AROUND ALL OF THE SIDE COVER..and see if you may have missed any side cover bolts ??????. if you got them all out ?, look at around the side cover at the edge where it meets the engine case, notice there are tabs in certain spots on the cover ?, these are your prying tabs..or in our case..hitting tabs..lol. this is where you put a long bar or flat screw drive against them from the back side, and whack at them..MAKE SURE YOU HIT THEM CAREFULLY !!..or you will damage the tabs and case !!!. all it takes is a few good hits to loosen the case right there. if you watch carefully when your hitting the tabs..you can see the cover move off the engine center case. hit the tabs evenly !!!, in other words..knock at the tabs to where your hitting the cover to come off all even..DON'T KEEP HITTING THE SAME TAB/COVER SPOT !!. sooner or later the cover will come off. as its coming off, try holding the kick starter shaft in place. same goes for the reverse lever, hold these in place as your getting the cover out/off..or else you will drop the kick starter thrust washer down inside the engine..that will suck !!..lol.

 

[shadetree]

Oh, great. I have an idea approximately how far I need to adjust it, so I guess I'll get it as close as I can and go from there.

In that case, I think it is time that I just go to town with a rubber mallet. I think I have all the bolts removed, but it just doesn't want to come off.

One last thing that I'm not 100% sure about but think I did right is the switch cover. The manual shows where it is and says to remove it, but I don't see anything I would call a "cover" there. No bolts are left in that general vicinity, though, so I think I have everything. I just wasn't sure.

Sent from my Moto E (4) using Tapatalk

the switch cover is just that metal cover that had a bolt holding it on the side cover, then your switches are behind that. dont remove the switches !!.

 

[derrick81787]

Thanks. Tapping on the tabs knocked it loose, and now I have a big enough gap that I can see inside there. It is loose and can come off, but it only wants to come straight off and I can't get it off because of the brake pedal. I see how to take the brake pedal off, there is just a spring a pin and a washer there, but everything is rusted on. I sprayed it with some penetrating oil and I'm going to let it sit, but I think I'm at a stopping point for today. Thanks for your help.

Sent from my Moto E (4) using Tapatalk

 

[shadetree]

Thanks. Tapping on the tabs knocked it loose, and now I have a big enough gap that I can see inside there. It is loose and can come off, but it only wants to come straight off and I can't get it off because of the brake pedal. I see how to take the brake pedal off, there is just a spring a pin and a washer there, but everything is rusted on. I sprayed it with some penetrating oil and I'm going to let it sit, but I think I'm at a stopping point for today. Thanks for your help.

Sent from my Moto E (4) using Tapatalk

worse comes to worse, you can always remove the foot rest, push the brake pedal all the way down far enough for the cover to clear coming off . and your welcome .

 

[Goober]

One last thing that I'm not 100% sure about but think I did right is the switch cover. The manual shows where it is and says to remove it, but I don't see anything I would call a "cover" there. No bolts are left in that general vicinity, though, so I think I have everything. I just wasn't sure.

Your cover might be missing. Click the links in my signature block to find parts diagrams and part numbers—lots of your parts are NLA ( no longer available directly from Honda)—but parts houses may still have. I have purchased many new parts on fleabay. Keep us posted!

 

[Bdelauder1987]

Most the time I've come to this,. It's the spring not putting the kicker in the correct home position. I know that much,. But when fixing it, I'm not sure, cause I never had to. A solution tho,. You said the kicker wasn't even on the motor,. Look up and see how tough it'd be to go inside and remove the spring or cut the kick shaft in half so it doesn't contact but also doesn't lose seal for your oil. First though,. I'd get some channel locks or vice grips,. And hrab that shaft and try to turn it backwards while it's running and see if that stops it. If I remember right,. The traxs kicked forward,. So you'll turn it back and try to return it to home position.. never know,. May just have just build up holding it off a tad . Good luck

 

[derrick81787]

Okay, I got in there, removed the kickstarter, and installed it correctly. So far that has been the easiest part of all of this.

Now, I'm following the instructions from the manual on how to reassemble, and I think I am missing pieces. I was meticulous in setting aside all those small pieces that I removed, and I checked for pieces falling out when I remove the cover, but I am convinced that I did not lose these pieces. I think they were missing from whoever worked on the kickstarter before. I've attached two pictures. Can you guys tell me what you think I am missing? I think I am missing the clutch lifter cam, clutch lifter cap, a spring, and the ball retainer. Is that what it looks like to you?

I drove this prior to taking it apart. The kickstarter clicked loudly which is what caused me to take it apart and work on it. Other than that, it ran and shifted, but they were hard and kind of jarring shifts. Is that how this would behave with these missing pieces? I guess if the clutch lifter was missing, then I was basically shifting without using the clutch which I imagine would be rough.

Does anyone know where I could buy these pieces? I also need a new gasket if anyone has any recommendations for that. it turns out that the reason I had so much trouble getting the cover off was because someone used RTV instead of a gasket and so it was basically glued on there.

Thanks again for your help.

Sent from my Moto E (4) using Tapatalk

 

[Goober]

Great job!! Hard for me to tell if anything is missing so I will post some parts pages

 

[derrick81787]

Thanks. That matches what is in the manual, except this image is more clear. It looks like I'm missing parts 14, 11, and 10 from the right crank case diagram. I'm surprised it could shift at all without those.

Two out of three are cheap and available. The lifter is unavailable, but at least I know what I'm looking for. Thanks.

 

[derrick81787]

The part labeled 10 in that diagram is the clutch cam plate (part #22820-HC4-000), and it is unavailable seemingly everywhere. However, part #22830-HC4-000 off of a Honda Foreman 400 is easy enough to find. Does anyone know if I can get away with using the Honda Foreman part? Is there an aftermarket part or something?

Sent from my Moto E (4) using Tapatalk

 

[shadetree]

here is one I found on ebay---> https://www.ebay.com/itm/1988-88-HO...d11d9dc:g:naUAAOSw1DtXHTBq:rk:46:pf:0&vxp=mtr . toss him an offer of 40 bucks shipped, see if he bites ?. there is some parts there that you don't need for that side ?, but hey..never hurts to have extra !. ang gawd..that motor was sunk, and left to rust with water in it !..lol. don't be surprised if you have to tear back into it to replace the clutches !!..lol.