[Bayou_Bengal]

I have a 1999 TRX 300 4x4, it was my dad's and mine, so I know where it has been and how hard it was riden.

I want to rebuild it, it needs alot of work, and I'll do the work part by part to save some money.

But for now, I want to fix what NEEDS to be fixed.

The two biggest problems the wheeler has right now is it whines real bad, and it is hard as H3ll to shift up and down. To get it to shift down somtimes I practically have to stomp the shifter. Has anyone had these problems and know what could be causing them?

Any advice would be great. I'm almost sure I'll need a new clutch, but I could be wrong.

 

[Helmut]

Try adjusting the clutch free play and see if that helps. It's located on the right side of the engine, an adjusting screw with a locknut. To adjust, loosen the locknut, slowly turn the adjusting screw counterclockwise until you feel resistance. Now, turn the adjusting nut clockwise 1/4 turn. Hold the adjusting screw while you tighten the locknut back down.

As for the whining, have you checked the gear oil in the transfer case and both diffs to make sure it's at the correct level?

 

[Bayou_Bengal]

I can't access my wheeler right now, but will be able to in two weeks. I'm writing down the possible fixes for the problems.

I wouldnt be surprised at all if the gear oil is low. We've never had it checked or changed since we bought it back in 99'. Plus there is some oil/dirt residue on the transfer case, that wasn't there before it started whining.

As for the clutch, I'll give that a try. I wouldn't be surprised though if I need to buy a new clutch assembly though, I rode that wheeler hard when I was younger and dumber.

Thanks for the tips.

 

[Bayou_Bengal]

Got to work on my wheeler some this weekend. I adjusted my clutch and that fixed the shifting problem for the most part. I had to adjust the shift lever up some though, I think it was bent and hit my floorboards on down shifts, but shifts flawlessly now.

As for the whine, the transfer case was low on gear oil. I added some and went riding and it quit whining, however it leaks. It looks like the leak is coming from where it connects to the engine. Do you guys think all I need to do is replace the gasket or could it be somthing more serious? If it's just a gasket I can fix that in two weeks when I go back up where my wheeler is.

 

[Bayou_Bengal]

Also, if anyone has a downloadable shop manual for this year and model, I'll pay for it through pay pal....unless someone has a link to a free download.

 

[shadetree]

Got to work on my wheeler some this weekend. I adjusted my clutch and that fixed the shifting problem for the most part. I had to adjust the shift lever up some though, I think it was been and was hitting my floorboards on down shifts, but shift flawlessly now.

As for the whine, the transfer case was low on gear oil. I added some and went riding and it quit whining, however it leaks. It looks like the leak is coming from where it connects to the engine. Do you guys think all I need to do is replace the gasket or could it be somthing more serious? If it's just a gasket I can fix that in two weeks when I go back up where my wheeler is.

it's leaking from the front drive shaft ??..gotta give alittle more detail as to '' where it connects to the engine ''..lol..there is alot of places these connect to the engine..transfer case leaking ??..front drive shaft from your transfer case to the front differental ??..if it's the transfer case drive shaft output seal..or the front differental case seal..these are easy to replace...if it's the transfer case gasket..thats also a easy fix as for replacing it.

 

[shadetree]

Also, if anyone has a downloadable shop manual for this year and model, I'll pay for it through pay pal....unless someone has a link to a free download.

try locating a manual from this sight..if there isn't one..helmut may have one ??..you can always order a service manual from clymers or just online.

 

[Bayou_Bengal]

Ha, yeah sorry about the vague description. It looks like it's looking oil from the connection of the front gear case and the drive shaft, if that's the case then it I should be able to replace the oil seal to fix the problem right?

Will a complete engine gasket kit come with this seal?

 

[Helmut]

Ha, yeah sorry about the vague description. It looks like it's looking oil from the connection of the front gear case and the drive shaft, if that's the case then it I should be able to replace the oil seal to fix the problem right?

Will a complete engine gasket kit come with this seal?

Yes, just replace that seal and I sent you a private message.

 

[shadetree]

no need for a complete engine gasket kit..you just need that transfer case out put seal..only about 5 or 6 bucks..give or take a dollar or two.

 

[Bayou_Bengal]

Thanks guys.

The reason I was thinking about getting the complete engine gasket kit is when I really start digging into the guts of the bike during the rebuild I'll want the gaskets handily avaliable.

But for now I guess I'll just order the seals for the gear case.

what have yall found to be the best/cheapest parts store for new oem parts? I'm looking at ordering the parts from cheapcycleparts.com.

 

[shadetree]

Thanks guys.

The reason I was thinking about getting the complete engine gasket kit is when I really start digging into the guts of the bike during the rebuild I'll want the gaskets handily avaliable.

But for now I guess I'll just order the seals for the gear case.

what have yall found to be the best/cheapest parts store for new oem parts? I'm looking at ordering the parts from cheapcycleparts.com.

if your gonna rebuild it from the ground up..then yeah..get the complete engine gasket kit..as for where to get the parts..i use bikebandit.com alot..they have decent prices ..and pretty good at shipping time.

 

[shadetree]

quick update, 24x9x11's for rear, 23x8x11's for front, itp mudlites are on order !!. next upgrade..warn xt25 winch..that's gonna take alot more time..as i got to figure and plan my best mounting spot..which i think i've got figured out ?!..lol..just a matter of doing it..never enough time !!..lol.

 

[Bayou_Bengal]

Quick update on my project: I changed the oil seal between the middle drive shaft and the transfer case, it fixed the leak and the whining noise. I adjusted the clutch play and position of the foot shifter to get that working correctly.

Next up, new front bearings and seals, new brakes (trying to decide whether to just get pads for a temporary fix then get the disc kit later or go ahead and get the disc kit), and I need to get a new front fender. Further down the road(aprilish), I'll be swapping out the rear end with either a 350D's or a Big Red's, whichever I can get the easiest and cheapest. Big plans, big plans.

For the front fender, I was wondering if anyone knows how interchangeable the different years are? For example, mine is a 99, could I mount set from 94' on the front?

And I'm sure some of you saw, but once I get the new fender for the front, and new splash guards I'll be trying out the new DIY camo dip kits for the frond and rear fenders along with the gas tank.