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Discussion Starter #1
Hi there, I have a 2005 trx300ex that decided to lock up on me last fall. So I spent the winter tearing it apart slowly and rebuilding it in my spare time. I found out that the piston rings decided to blow apart and lock the piston in the cylinder destroying the sleeve in the process. Since I cant leave anything stock I decided that a upgrade was in order so I ordered a 330 big bore cylinder for it with a hotshots cam(1058-1). I ended up splitting the case to clean it completely out and started to put it back together. I almost have it together now but I've run into a issue.....when I bench shift the trans I can get it to shift into 1st,2nd,3rd and reverse. It will not shift into 4th. The trans worked just fine before I took it all apart even after the motor quit.

Does anyone know what I may have fudged up or is this normal till the motor runs?

I should probably say at this point that this is the first time I have ever took anything like this apart. (Normally the engine has 8 cylinders to it)

Any help would be appreciated.

Another thing to note is that I was downshifting into 3rd when it locked up on me
 

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wow..you did a number on that piston !..lol. as for why it wont change gears ?, my money say's you did not install the transmission right ?. maybe a gear on wrong ?, shift fork not right ?, bad spot in the shift drum ?. yeah, its best to rip it back apart, and have a look before you put the motor back in the frame, now's the time to do this..not after you put the motor back in !..lol.
 

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Discussion Starter #4
Yea, it broke the sleeveand pulled it into the crank, that's why it was split to get all the chunks of sleeve out
 

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Yea, it broke the sleeveand pulled it into the crank, that's why it was split to get all the chunks of sleeve out
did you inspect the crank ?. the wrist pin and lower end area needs to be checked !.
 

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Discussion Starter #6
Yea, the crank and bearings check out good (got lucky there) and it got a new wrist pin with the new piston. No excess play where it shouldn't be
 

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Discussion Starter #7
So I got it back together after blowing it apart again and fixed trans issue. Now I'm thinking that my ignition control module is shot. I have no spark at the plug. After some wire chasing I figured out that I have a signal going into the box but no signal coming out to the coil.

My question is first of all am I right in thinking its shot and if so is it worth looking for a upgraded one to complement the other upgrades? Was also thinking about a upgraded coil, any ideas on a good one?
 

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Discussion Starter #8
Never mind, I'm an idiot. The damn kill switch was on, lol. Its runs but it almost sounds like the timing chain is loose. I had to put a new chain on it with the rebuilt as I had to cut it off when i tore it down so i highly doubt that it is stretched. How often does the tensioner go out on these quads? Any way to tell if its bad?
 

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Never mind, I'm an idiot. The damn kill switch was on, lol. Its runs but it almost sounds like the timing chain is loose. I had to put a new chain on it with the rebuilt as I had to cut it off when i tore it down so i highly doubt that it is stretched. How often does the tensioner go out on these quads? Any way to tell if its bad?
your not the first, and wont be the last to '' forget '' the kill switch !..lol. remove the tensioner, let it extend, stick back in like your gonna bolt it up, your looking for about 1/2 before you reach cylinder. and it should lock once it extends. right chain on it ?. how was the chain guides ?. was everything installed right ?.
 

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Discussion Starter #10
Its 110 link from niche, same company as the cylinder. I never counted the links on the old one. Chain guides look good and everything was installed per the shop manual. I'll have to check the tensioner and count links when u get home as I'm at work now
 

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Its 110 link from niche, same company as the cylinder. I never counted the links on the old one. Chain guides look good and everything was installed per the shop manual. I'll have to check the tensioner and count links when u get home as I'm at work now
I only use D.I.D. cam chains. what shape was the cam sprocket in ?. did you inspect it ?.
 

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Discussion Starter #12
Sorry, it's been busy here. Just getting back to this.

Counted links, confirmed 110 links.

Cam sprocket is solid, not even a nick on it

Sound has stop traveling, sounds in bottom end only,

Local Honda shop gave me somethings to try before I yanked it back out, tried all but none helped.

So now I'm pulling the engine and yanking it apart to see if maybe a bearing went out or not. If I cant figure it out this go around I'll probably keep it for parts for my other 300 and source a completely different engine for this one
 

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Discussion Starter #14
So I just bought the tool (didnt relise it was $10 lol) went through it and found some play in the right side crank bearing so I ordered both. Spec out the crank again found it within spec. Check out the timing chain guids and have some wear on the tensioner side but not that bad (can upload images if wanted) no other obvious signs of things wrong so I'm at a lost as to what it is. I don't think that the crank bearing would have been bad enough to make this noise. Will have to update when I get parts in
 

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and you know for a 100% fact, there is no play at the wrist pin on top of rod...right ???.
 

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and you know for a 100% fact, there is no play at the wrist pin on top of rod...right ???.
There is no play at all on the wrist pin at the piston
ok, and how about your cam chain adjuster ?. did you set and adjust the valves on the correct stroke ?.
Not sure on the timing chain tensioner, going to check it upon assembly. Valves were adjusted on the correct stroke.

Parts should be in tomorrow and I'm hoping to put it together this weekend if I have the time between fixing 2 other pickups.
 

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There is no play at all on the wrist pin at the piston
ok, and how about your cam chain adjuster ?. did you set and adjust the valves on the correct stroke ?.
Not sure on the timing chain tensioner, going to check it upon assembly. Valves were adjusted on the correct stroke.

Parts should be in tomorrow and I'm hoping to put it together this weekend if I have the time between fixing 2 other pickups.
2 trucks huh ?..they must be fords ??..lol.
 
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