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Discussion Starter #1
Hey guys, new to the forum, but pulled up a lot of great info before getting the 4-wheeler, and some really great guys and info on here! Glad to be a part of it, and hoping I can get some help. I did some trading for a 94TRX 300FW that was in really good shape, but needed some love. So, over the last few days, I've changed out front and rear case oil, oil and filter, and some other nit pick stuff. When I got it, it didn't smoke a bit, which for it's age was impressive and a good sign of proper maintenance. WRONG! There wasn't a half quart of oil in it and was like sludge. After changing it and the filter, it smokes like a freight train! Used Honda oil and filter from the dealer here in town, and even took the filter cover off to make sure I didn't install it backwards, so it's installed correctly. My guess is I'm hosed and have to fork out a crap load for an upper build and valve job! Any input, suggestions? I read another guy had the same issue, and everyone said that it was weird and almost unheard of, but here's another case of the same issue.
 

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Unfortunately I'd say your right, top end build. Does the smoke get worse as the engine warms up or does it start to clear?
 

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very possible he could have had straight lucas oil stabilizer in it, that will stop smoke, then when you put fresh oil in it goes to burning.

its not a big deal, download a service manual, study how to remove and reinstall top end, and you will be into a full rebuild for under $500 with OEM components with a new cam chain, rebuilt cylinder head and bored out cylinder.
 

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Complete top end re-build and flush out the bottom!! Change clutches to usually a burned up sludgy motor means burned up clutches..
 

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I think you need to open this motor up and do a full break down and cleaning, if oil was sludge up and thick, GOD Knows what else is in there
ONLY way to do it RIGHT is with a case split , major cleaning, and tear down, and then you can inspect all internal parts, and replace as needed
just think of it this way, do it right once and it will last a LONG time if you take care of it
sucks, but, these days, more scammers out there than not<

best of luck to you, a LOT of 300 IMIO experts here(I ain;t one of them ) but there are some great guys here that know them very very well, that can advice you if you decide to tear it down yourself and you need help
just ask and they will help you get it back up and going!
 

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chances are, if there was not oil in it to start with ?, then I would say the rings/cylinder is shot, and needs a top end rebuild. if it wasn't smoking from the get go ?, it's because it already burnt all the oil out !.
 
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Discussion Starter #7
Well, when I changed all the fluids in the crankcase and both axles, I didn't have a total of a quart in a 1 gallon paint can! I figured there wasn't enough oil in it to smoke when I went and looked at it, rode it and a good shake down. Dipstick was showing low and dirty, but I always change all fluids, filters, plug and everything anyway, so it didn't really bother me since it ran like a top, didn't smoke, no ticking valves or any sights or sounds of outright neglect. Really upsetting since I got it for duck season this year, and it's coming fast! I'm pretty well mechanically inclined, but having my doubts about such a project, and only been in the town I'm in since last February, when I got married, so don't know a good, reliable guy to take it to, or where to even get the parts that I need. I'm a little hot, but mostly dissapointed as a fella can be over this!
 

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Discussion Starter #8
And to answer your question SamUK, yes, the longer it runs the worse it gets. Even at idle, there's some smoke, but hit the throttle a touch, and you'll kill every mosquito with a 5 mile radius of my house! And I greatly appreciate all the input and if I have to go through the trouble of tearing it down, she's goin down! No since when your that far in to not do it right. I've always been a firm believer in that and always thinking ahead, so yes, timing chain, clutches and all, unfortunately. I won't say that my cup runneth over with cash with all the tools, equipment and trailer issues this year, but for another $150-$200 for clutches and what nots, I'd be a fool not to. I just sold a 3 wheeler tje 1st of the year that I bought brand new in 83, and it ran like a dream, hated to, but health issues dictated it, and won't be doing any major trail riding or anything like that with the 300, just something to leave at duck camp for the season to get back and forth from the house to where I'm hunting that day, so got to have something to help cover the 6,540 acres!
 

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this may not be something everyone would do, but you can dump about 1/2 a quart of lucas oil stabilizer in there and it will help keep the oil consumption to a minimum.

I don't always suggest it, but when a guy is in a pinch for cash/time, you can run that with no issues and it usually helps significantly until you can get down and rebuild it.
 

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Discussion Starter #10
I was scared to put anything in it, but I'll give it a shot and see what happens. I know it's got to be done, but if I can limp through for a bit, then I'll have the time to do it like I want to. Thanks for the tip!
 

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I see your in TN ?, g&h does top end kits, they are in your neck of the woods for the top end rebuild kit, send them yours, they send you a top end kit to bolt on. not sure on gaskets though ?. you will need a gasket and tools to change out the cam chain from the right side cover. word from the wise: anytime you buy used ?, expect to put money into it to make it right !. most times, past owners...DO NOT TAKE CARE OF THIER ATVS !. if you get stumped ?, come back on here, we'll guide ya !. but your best bet is to down load or get your hands on a copy of the service manual for your atv !. and if worse comes to worse ?, haul the puppy over here to me, we'll get it fixed up !. ( you supply the cash to buy all parts, I don't charge no where near what a dealer will charge you ! ).
 

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I was scared to put anything in it, but I'll give it a shot and see what happens. I know it's got to be done, but if I can limp through for a bit, then I'll have the time to do it like I want to. Thanks for the tip!
problem with doing this IMO is, one, your only doing more damage to the motor, two, if right now all you need is a top end, and you run it with crap in there it could eat parts ups you maybe wouldn't have to replace, costing you more in the long run?
next, if this motor is bad NOW< its low on compression I bet, your NOT going to have very much power
might get you going a bit, but what if it gets you out back and dies there? now you have to find a way to get it back home?

you already know there is a issue's why keep making them bigger?

your atv , do as you want
but I doubt this is a smart move, to keep running it as is?
what if a piston comes apart and takes out your cases?? way more costly repair on your hands!
 

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Discussion Starter #14
Thanks shadetree and manning, greatly appreciated! I ordered a Clymer manuel this morning, and going to do some homework. I've slept on it, and definitely heeding the advi e not to put Lucas in it and take a chance of costing myself even more, excellent advice. It can't be that bad at this point, it still pulls like a mule, and has good acceleration, so she'll sit and the wrenches will come out. And shadetree, if ya weren't 350 something miles away, I'd definitely take ya up on your offer! About the closest I'll be to you will be Walnut Ridge, the ol duck camp. I've always had bigger things done by someone I know or referred to by someone, so I'm a bit nervous about this. How long should something like this take, typically? I'm mechanically inclined, have good common sense, and tons of nice tools, but not pullers, ring compressors and some of the specialty tools I think I'm going to need, Auto zone I suppose? This is absolutely awesome, I wish I'd got on here or one like this years ago, I'd definitely be more informed and understand some of this stuff a lot better, and can't tell all y'all how much I appreciate your help, comments, advice and opinions, THANKS! Definitely more questions to come lol! Thanks again guys!
 

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also a good source of info on these things is YOUTUBE< there are tons of good videos on HOW to do these repairs, so , wouldn;t be a bad idea to watch a few before taking it on,
I know I find seeing something done a BIG help and confidence booster when I tackle new things
as some times it easier to see how easy/hard something might be seeing it done rather than reading how its done
/just food for thought!
 

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Discussion Starter #16
Funny, I was just watching a few, lol. That's a handy tool, everything in the world is on there, so I typically look on there before tackling something new and see how much crap I'm fixing to get myself into!
 

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Thanks shadetree and manning, greatly appreciated! I ordered a Clymer manuel this morning, and going to do some homework. I've slept on it, and definitely heeding the advi e not to put Lucas in it and take a chance of costing myself even more, excellent advice. It can't be that bad at this point, it still pulls like a mule, and has good acceleration, so she'll sit and the wrenches will come out. And shadetree, if ya weren't 350 something miles away, I'd definitely take ya up on your offer! About the closest I'll be to you will be Walnut Ridge, the ol duck camp. I've always had bigger things done by someone I know or referred to by someone, so I'm a bit nervous about this. How long should something like this take, typically? I'm mechanically inclined, have good common sense, and tons of nice tools, but not pullers, ring compressors and some of the specialty tools I think I'm going to need, Auto zone I suppose? This is absolutely awesome, I wish I'd got on here or one like this years ago, I'd definitely be more informed and understand some of this stuff a lot better, and can't tell all y'all how much I appreciate your help, comments, advice and opinions, THANKS! Definitely more questions to come lol! Thanks again guys!


If you get stumped too bad I'm only a couple of hours down the road.. I've done a couple and have Shadetree on speed dial...lol


Sent from my iPhone using Tapatalk
 

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Top end isn't too bad.

Get you a cheap set of pullers on Amazon. You'll use them more than you would think on things other than ATV's.

G&H does good work but looks like they're still a ways away from you.

Top end isn't too bad. Free factory service manual download here. Just take your time and take pictures of stuff before you take it apart. If you get stuck it's easy to look at the pictures to see what goes where.

https://drive.google.com/drive/folders/0B_TKSTsdx3KNRlRpdjBDQjl5TGs
 

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You shouldn't need a puller for your centrifugal clutch, most just come right off on 300's with a tap with a rubber mallet.

if that doesn't work, a 2 jaw puller with a large clamp on the arms to keep them from spreading gets them off.
 

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get-r-done !!. I remember back 20 plus years ago, started working on an atc200es ( it was free ! ), I dug in, never even thought of looking on youtube ( and not sure youtube was around then ? ..lol ), tore that puppy all apart, fixed it up, sold it for 2500 bucks, been doing it ever sense !.
 
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