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Honda TRX300 Kick Start Clicking

8234 Views 22 Replies 6 Participants Last post by  derrick81787, 
D
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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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 :)
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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 :)
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