Thanks to the coaching and help from you guys in the forum, I am learning the ins and outs of my 25 year old ATV. Last week I assumed the problem was the starter, but after removing it and putting it back in, I have concluded that it is not the starter. The actual starter is working.
Here is the problem:
When I attempt to start (using the electric starter) the ATV, a very loud rattle comes from the casing area that houses all of the gears. I have opened that up, taken the gears out, lubricated the area and checked for loose parts and worn teeth. Still LOUD rattle and will not start.
Any ideas what I should do to fix the problem.

Thanks
Matt

welcome to the forums..if i'm understanding you right..then your starter's one-way bearing is bad . to see what i'm talking about..you will need to remove the flyweel and the big starter gear behind it..try turning the big gear while its sitting in the flywheel ?..it should only turn one way..and lock when you try spining it the other way.

 

Yep, I agree. Sounds like the one-way starter clutch is bad. Sometimes, when they go bad, they can make an awful noise when trying to start the ATV.

 

yuppers..it's more of a loud clanking noise if you ask me !..lol. this is what i'm replacing on my '86 trx350 fourtrax as of right now..both one-way bearings are bad on my bike matt..you can take a gander at my project in the DIY section..it shows a few tear down pics..i just got the flywheel off today..i have not taken a pic of the bearing..i guess i should of..before mentioning it ??..lol.

 

And welcome to the forums.

 

Thanks Guys!
Ya. It is real loud.
I will check out your pics.
When I get in there, what part(s) do I need to replace? or can the existing parts just be repaired?
I plan to attack it again tomorrow.

 

You need to replace the one-way starter clutch that bolts to the back of the flywheel and maybe the big starter gear that fits into the one-way starter clutch. It depends on how bad the starter gear is wore as to whether you will have to replace it. It's best to go ahead and replace both if you can. The problem might be finding one for that model, because a lot of parts have been discontinued.

 

here ya go !. it isn't pretty..but it shows you what is bad. it's the one-way bearing.

 

For a picture of what the one-way starter clutch looks like, go to the Ebay link below. The one in the link is for a 350 Rancher, but yours will look similar. It also shows the big starter gear that fits into the one-way clutch.

2002 TRX350 Honda Rancher 350 starter one way clutch | eBay

 

All of this bolts to the back of the flywheel as you can see in the page that Shadetree posted above in the attachment.

 

yeah..it's got a few torx bolts holding it in the back of the flyhweel.

 

i'm restoring the same bike as you matt..mine is comming apart one piece at a time !..lol.

 

I really appreciate all of your help and suggestions.
This forum is great and you guys are very quick to respond!
So, if I cannot replace the part, the ATV should still be able to start with the kick start, correct?

 

That's correct. If I'm not mistaken, the 400EX one-way starter clutch will work.

 

By the way, the centrifugal clutch on the right side of the engine also has one of those one-way bearings like in the starter clutch. If this bearing goes bad, you won't be able to use the kick starter to start the ATV. And also, you won't have any engine braking. This bearing is located on the inside of the centrifugal clutch.

 

here's a pic of a one-way bearing..it's from the clutch side..but the same bearing is also on the starter/flywheel side..it's just reversed on the lobes.

 

Except for the outer edge of the cage is made a little different on one side because the round flange has to fit over it and hold it in when you bolt the outer flange to the flywheel. Other than that, it's identical.

 

I need help with a similar problem!

hey guys, i was just wondering about a problem i have with my 1997 4x4 Fourtrax TRX300. i can go offroad fine anywhere but as soon as the quad goes on road i get a loud clicking sound coming from the back end, the funny thing is that the noise only happens maybe two or three times in say a hundred metre stretch of road. need urgent help!

 

hey guys, i was just wondering about a problem i have with my 1997 4x4 Fourtrax TRX300. i can go offroad fine anywhere but as soon as the quad goes on road i get a loud clicking sound coming from the back end, the funny thing is that the noise only happens maybe two or three times in say a hundred metre stretch of road. need urgent help!

i am definitely no utility atv expert but it sounds like your rear differential needs some attention

 

il have a look at it il post back what i find out:S its strange as its only on road though? not a sound offroad in any gear, even top end 5th.

 

i would start looking at the rear differental....rear brakes....maybe a stick is lodged in somewhere ??..bearings bad ?..can be anything. and are you sure it's the back..and not the front ?..only way to tell..is too look !!..lol.

 

well im going to have a look at her today, hopefully i wont find anything bad (fingers crossed). anyway il post back what i find to see if any of you Honda Genius's can help me out again

 

had a look today, the noise doesent seem to be coming from the rear diff, it sounds like its coming from the driveshaft uv joint connected to the engine, is it possible it could be sliding in and out of drive because its okay on off road but on road it just makes very violent clicking/banging noises! need help dont want to lose my monster!

 

Thnaks guys!

problem solved! just checked the diffs and they were bone dry! filled them up with Hypoid 80 and the nosie is gone! thanks alot guys for the help and il be sure to come back if i find another problem or need help!

yet again thanks to everyone! :laugh:

 

Guys yet again i have another problem, i bought a pair of innova mudgear tires for the bike, the tyres are fitted on the front and have signifcantly more tread than the completely bald back pair of original duro excavator tires. the clicking has returned know the tyres are fitted, and yet again the clicking is completely absent offroad! could the new pair of tires with there extra inch of tread be causing an inbalance with the 4x4 or something? please help! i need the bike urgently!
thanks

 

tires or no tires..makes no difference when it comes to this clicking noise..did you re-check your rear differental..see if it leaked gear oil ?..rear brakes look good and working right ?..all bearings and seals in the rear differental look good ?..feal good ?. jack the atv up off the floor...all 4 wheels must be off the ground..spin the rear wheels..listen for this clicking noise ?..i don't see what difference either off road..or on road..would make a difference..if it's gonna make this noise ?...then it's gonna do it everywhere...this is what i'm thinking anyway. i'd start with jacking it up..and looking at the rear end first.

 

hi guys just wondering if i can put castrol 4t power racing motorcycle oil in SL, honda fourtrax 300 x4 2000

 

I just replaced the one way clutch on both of my 86's it is still available. altusmotorsports.com is where i got mine.

 

New here have the same problem. But I can turn the small gear in the starter housing and it does turn only one way. And locks the other way. So how do I know it's still might be the one way bearing?

 

You should look for any signs of wear on the surfaces that the bearing contacts - they must be very smooth to work when under load.

 

Ok I'll do that. Thank you for the quick reply. How long should it take to get to the bearing. I'm a ASE certified mechanic. And have done some repairs on quads just not that extensive.

 

You sure it’s not the fuel pump rattling?