Honda TRX300 Kick Start Clicking

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.

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.

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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.

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I know this has gone on for way longer than it should have, but I wanted to post an update. I've had some trouble with getting parts and shipping and things, plus I can only work outside and it's been cold lately, but I finally got everything back together. I even bought a kickstart pedal and put that on there too. I was able to use the kicker to start the engine, and it started easily and was no longer clicking. However, after running for a few minutes oil started to spray from the top of the right crankcase cover where the oil path pipe meets the cover. When investigating it, I realized I was supposed to replace those copper sealing washers with new ones but didn't, so that is probably the culprit. I was hoping to find some locally, but I can't find the right size, so it looks like I will have to order them. Other than that, I believe everything is working. It was nice to be able to start it with the kicker and see that it all worked the way that it should.

I'll post one more update after I replace those washers, and hopefully it will say that I'm driving around and everything is fine. Thanks for all your help on this. I went from having no clue what I was doing to feeling like I actually understand how things work in there, at least somewhat.

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