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Honda TRX300 Kick Start Clicking

8208 Views 22 Replies 6 Participants Last post by  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.
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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.
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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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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.

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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.

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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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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.
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?

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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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I have the old ones and had them on, but it still leaked from the connection. The manual said to replace them with new ones, so I'm hoping that's the issue. They are designed to be crushed in order to make the seal, I think. I don't know. Hopefully that's the issue. It's pretty straightforward to put that thing on, so I'm not sure what else it could be.

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