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Honda TRX300 Kick Start Clicking

8235 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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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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ehhhh..what happened to the old sealing washers ???? but thanks for the update !.
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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