[Fordtrucker]

I recently acquired this 1998 Honda TRX300EX, it has a 1986 Honda ATC 350X engine in it. I got it for $20, so that leaves me with the rest of my budget of $250 to fix it up, i will be starting a WTB thread soon to hopefully get it going. The first picture is what the seller sent me, the second is of the damage and the rest are as it sits now. Obviosly the engine it the biggest issue, the plan is to clean and sand the area well and patch it with some aluminum i have laying around. The second thing I'm going to tackle is the fact that the front plastic is gone, and the rear is very badly damaged. I believe I can fix the rear though. Chassis wise it is sound. If anyone has a picture of how the sprocket is attached, i would appreciate it. The PO tore the stator cover and sprocket off and lost a lot of hardware so I'm not sure what keeps it on, any help/advice/guidance is appreciated. Thanks

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[fishfiles]

looks like the chain ate the case from not being adjusted periodically , is it leaking engine out ? If so was it ran low of oil at one time would be a concern ------------ there is a case protector you can get that protects the case from the chain , I would use Devron aluminum put and maybe some screen, and mold it so a case protector can go on top of the repair area

 

[Fordtrucker]

looks like the chain ate the case from not being adjusted periodically , is it leaking engine out ? If so was it ran low of oil at one time would be a concern ------------ there is a case protector you can get that protects the case from the chain , I would use Devron aluminum put and maybe some screen, and mold it so a case protector can go on top of the repair area

The previous owner said the chain "pinched" and broke the case. The chain has a lot of slack as well. He says he parked it when the chain pinched and than he noticed it blowing oil when he fired it up again. So who knows if any damage was done. It seems to rollover fine and shifts through all gears. I will get a picture of my repair material tomorrow. Also do you know what oil and how much? Thanks

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[Goober]

You will need a service manual no doubt. You can research part numbers using my signature block links below.
Here’s a couple of parts pics for you.

 

[retro]

I'd replace all of those busted cases. No way that output shaft is gonna stay put with the bearing busted out of it.

 

[fishfiles]

Two years ago my buddy bought his son a brand new Yamaha racing dirt bike , on the third week he had it , it started leaking engine oil , he took it back to the dealer and they wouldn't warranty it , the chain had ate the case , they said it is a maintenance issue ----when you get this all resolved , be sure to stay on top the chain adjustment so it doesn't happen again ------ oh , he puttied it up and traded it in to another dealership -----

My CSI mind could think of two scenerios of how it went down , one is the PO parked the bike where they could see it leaking oil and stopped riding it before doing damage to the engine , the other is they parked in the grass or mud and never seen the oil leaking , ran it till there was a problem with it running hot , ticking or knocking and then stopped riding it

 

[Fordtrucker]

Here is my patch material. I don't know if I mentioned this, but the previous owner lost all but three of the stater cover bolts, Napa does not carry them so i gave to find some online, if anyone here has any I'd be interested. After school i am going to crack off the cover again and clean it up. Does anyone know if I need a gasket or can i get way with high temp rtv? Thanks

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[fishfiles]

HondaBond 3 or YamaBond is the best thing for covers and cases , the rtv can ooze out inside the case , fall off into the engine and clog up a journal

 

[Fordtrucker]

HondaBond 3 or YamaBond is the best thing for covers and cases , the rtv can ooze out inside the case , fall off into the engine and clog up a journal

I am going to try to make a gasket with some material we have and seal with indian head. I am stopping at the parts store after school and ill see if they have any of that first though.

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[Fordtrucker]

I got a little bit done, stopped at hardware store and parts store, i got case bolts, no sealant. Gonna start cleaning it up to apply the jb weld and patch tonight i found pics and am missing the sprocket retainer i found a snap ring that fit though. Does anyone know what goes in the place u circled? Also do the parts in my hand look familiar? The seller gave them to me and i cant seem to find where they go. Thx

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[fishfiles]

In this pic , #6 is the clamp that holds the wiring harness in place

 

[Fordtrucker]

Progress has been made! I went tonight after school to pick up some plastic. Me and dad went 1 1/2 each way to pick it up and i just got in from installing it. I also got my propane tank filled up so sunday (hunting tomorrow) i will get the heater fired up and fix the motor case in the morning and hopefully get it fired up in the afternoon. I got the full front plastics, bracket, hardware, headlight, and nerf bars for $100, i know, i know, I overpaid but the plastic is damage free, uncut and right minty. As you can also see in the pics i am going through the SLOW process of removing the 7 layers of old paint to the original plastic.

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[Goober]

Wow great job!

Be very careful to reference the bolt thread and length you’re using to the specific location of the bolt in the parts diagrams. For instance The parts diagrams might show 6x12 (6mm x 12mm long) and as, in your pic, bolts nearly always flanged-head bolts. Always match the thread cut and use antiseize compound unless it’s engine-internal. Too long or too short can lead to catastrophic failure or irreparable damage to these hard-to-find parts.

 

[misterclean59]

Great job so far.

 

[Fordtrucker]

Progress! Things have been going much slower than planned but i have gotten somewhere I got a gasket made and installed sunday but not much else do to selling somthing at the last minute and turning my attention to getting that running again. Monday night we got the patch put on the engine and last night after school I managed to get her started, no ticks, knocks or smoke, in fact it runs pretty minty. The plan tonight is to get the chain thrown on and try to ride it. I've never driven standard only on tractor before so this should be interesting. Among other things i also managed to get the last of the green paint stripped of as well as stitching up a spot that was done poorly and testing the headlight. Now i just need to figure out the wiring for the light.

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[fishfiles]

nice on the patch job , good to hear it runs ----- I would see about getting a case protector and see if it can still be mounted ----keep the chain lubed and adjusted , you might want to look at the chain and sprockets right now , they maybe worn

 

[shadetree]

wonderful job !. but..if it was mine ( and we both know its not..lol ) I would just have replaced the whole side cover. I dont trust jb weld for nothing !..lol. deff get some kinda case saver !!..if the chain did it now ?, you can bet your last dollar..it will do it again..spec if the sprockets are worn badly ?.

 

[Fordtrucker]

Thanks guys, i am going to make a chain protector this weekend. I have always had good luck with jb and I've used it to patch engines before. The chain and sprockets look good, and the chain is very oily so it looks like he lubed it well.

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[donald4675]

Hello

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