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Discussion Starter #1 (Edited)
i've rebuilt a chainsaw or two, but nothing liek the 93 TRX300 mess i got myself into. had some leaking oil seals at the neutral and reverse sensors and the reverse cable arm shaft. when i took the right side crankcase off to get at cable arm shaft seal, the clutch cam plate, clutch lifter plate and the retainer ball all fell out.. once i get the old gasket material off, how do i go about reinstalling the crankcase cover with out all those parts falling out? are there special tools? flip up ATV on its side? the kick start shaft stayed with the crankcase cover so i presume there is additional concern on torquing that spring? can't find anything in the manuals about it. thanx jim
i guess the sound of the Beatles "Help" running through my head kinda ages me
 

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Hello, welcome to the forums!

Everything you need to know is in section 8 of the FSM for your 300. The kickstarter assembly and change clutch mechanisms are covered very well... You can block up the right side of the bike so it leans over and make it a lot easier to work on. Makes it easier on your back too. :)

Let us in on how it goes... Have a great weekend!
 

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Hi: This should help you out.

Kick Start TRX300

Start by temporarily putting the kick starter lever on the end of the shaft. This will help you to be able to hold it easier and to be able to turn it easier when you hook the spring. Next, hook the end of the spring to the hook down inside the case, but don't push the shaft in far enough so that the gears mesh because you need to be able to turn the shaft. Now, with the spring hooked, turn the shaft to the right until the ratchet goes all the way to the bottom of the ratchet guide and then push the shaft straight down so the gears engage. The ratchet should spring back and go to the top of the ratchet guide and stop. If you look at the ratchet guide, you will notice that it is ramped so that it pulls the gear teeth on the shaft apart when it returns. This keeps the teeth from touching and getting ripped off when the ATV starts.
When pushing the shaft in make sure the arm with the red dot is all the way down to red line.
See picture.
 

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Welcome to the forums! Lots of great help here :)
 
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You got a good start with information so far , the first time I done the right side cover of my 300 it was a disaster for me , it took like 4 times on and off till I got it all right , now I think I could do it with my eyes blind folded ------- some pointers : , be sure to get all the thrust washers in place , apply Honda Bond to the cover then apply the gasket to the cover and no Honda Bond to the case , so if you don't get it right then you won't destroy the gasket taking it off again , be sure to line up the index marks on the shift shaft or it will shift up and not down or vice-versa , put grease on the end of the kick starter shaft so the thrust washer doesn't fall into the case , as you won't be able to get it out if you drop it in there thru the hole right under where the shaft goes , don't force the cover on by tightening up the bolts , once you think you got the cover on right , don't put every thing back on before going any farther , check the neutral and revere lights for proper operation , check for shifting up and down with out starting the engine by rolling the tires back and forth , check the operation of the kick starter -----take your time and don't rush it and may the " Force Be With You "
 
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