92' TRX300 Shifting w/ Stator cover off - Honda TRX Forum
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post #1 of 28 Old 12-05-2018, 01:58 AM Thread Starter
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92' TRX300 Shifting w/ Stator cover off

Greetings folks, long time lurker / learner here. This place rocks, its an invaluable source of TRX repair info.

So maybe this will be a simple question for someone. First quick background: I'm chasing a no-spark issue that after replacing CDI, Coil etc ... lead me to examine the stator and pickup coil. While they tested within limits via the wiring, I still cracked open the side case to remove the stator.

Here's where the question comes in, while I had the cover off and testing the stator, my 18 year old thought it would be interesting to see how the shifter assembly works so he stuck the shifter petal back on and yanked up on it. He said he felt / heard a "clunk" inside

Soooo when I came back and heard this (after biting my tongue), I rocked the atv and it freely wheels around. I tried to shift it down, shift it up... nada. It seems fairly stiff. I've never been inside an atv transmission, nor the TRX300 specifically. Is it possible he could have tweaked something shifting it with the case off? I don't see anything on the exposed linkage that is preventing it from potentially shifting. I would expect it to drop into gear easily...but its obviously not doing that.

The neutral light isn't on... but I don't know if its shifted out of neutral or if those lights wont come on with the stator / pickup coil removed. Is there something on the right side of the bike that the shifter shaft connects to that could have gotten out of wack?

I really dont want to reassemble the stator side if there is something inside that is now broken or out of index or something weird.

Thoughts?


-DallanC
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Last edited by DallanC; 12-05-2018 at 02:04 AM.
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post #2 of 28 Old 12-05-2018, 01:25 PM
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I presume it's a TRX300, but what year and is it an EX, FW or what? What's the VIN? I'll try to walk you through this - the pic is a great help, looks like everything is in place so together maybe we can figure out if there is anything wrong. Steve
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post #3 of 28 Old 12-05-2018, 03:59 PM Thread Starter
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I snapped the model # as I ran out the door headed to work. If you truly need the VIN I can dig that up. But, the bike is a plain 1992 TRX300 2wd. Its been a great bike, not abused... it just lost spark hence starting to dig in.

What I'm trying to figure out is if i need to pull the clutch cover to see if that linkage is setup. I ordered a gasket just in case last night.

Tonight, I think I need to partially disassemble the gearshift linkage / shift drum and see whats up with that.

All actual gear shifting is driven from the Stator side right? The shift shaft only drives clutch disengagement on the clutch side?


-DallanC
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post #4 of 28 Old 12-05-2018, 04:27 PM
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OK - the shifter should work from what I can see in the pic - all the parts are there - get the rear wheels off the floor - you should be able to shift the transmission by rotating the rear wheels and shifting in the direction desired. If the shift shaft is pulled out too far (more than about 1/4 inch) it can be disengaged from the clutch release lever and then the right side would have to be pulled off to re-engage it, but I see no reason it won't shift as long as the engine or rear wheels are turning.
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post #5 of 28 Old 12-05-2018, 04:44 PM Thread Starter
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Thank you!

I'll dig into it a bit more tonight. Freaking cold this time of year in the garage so I bought a propane torpedo heater. The bike will roll easily, but I'll jack up the rear and spin the wheels a bit more to see if I cant get something to engage.

I wonder... wonder if the shifter shaft pulled out a bit, and when he tried to shift it, it bound up the clutch linkage into a "released" state, so it is in gear but the clutch is free spinning. Either way, sounds like I need to pull that other side /sigh

What a pita... and I still dont know if the new pickup coil will solve my spark issue LOL.


-DallanC
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post #6 of 28 Old 12-05-2018, 04:50 PM
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I don't think the clutch could be held in release - if the shaft was pulled out, it would either bind up trying to push it back in, or it would simply not disengage the clutch which would affect shifting with the engine running, but it shouldn't affect shifting when the engine is not running
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post #7 of 28 Old 12-06-2018, 01:48 AM Thread Starter
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Ok so I took off the gear shift linkage, dogs, plate, detent etc. Everything there looks good. The shift hub seems to have alot of play... IDK if this is normal or not.

Apologies for semi crappy video... but it gets the point across. Also apologies for the noise, its 20degrees right now and I had a torpedo heater blowing on me

https://youtu.be/sTc6A6H0EDc

I put all the shift linkage back together, the shifter shaft inserted all the way in easily. I stuck the shift pedal back on and put quite a bit of pressure on the shifter both up and down, nothing moves in the tranny. Rear wheels still free spin. I tried turning over the crank by hand via the flywheel (spark plug is out so it turns over semi-easily) and working the shifter but no go. I really dont want to put a crazy amount of force on the shifter yet. Still kicking around if I should crack open the clutch side cover.

So wierd, there has never been a tranny issue with this machine in the 15 years we've had it. IDK why it would go south on me now while chasing the electrical issue.


-DallanC
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post #8 of 28 Old 12-06-2018, 03:15 AM
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I think you are going to have to take the right cover off - there is a bolt on the right end of the shift drum that holds the reverse lock in place and limits the movement of the drum - I'm going to guess the bolt is loose or broken or the shift drum is broken or some other anomaly has occurred - you will probably have to remove the clutch to see what has happened - I doubt it was caused by your son, it was most likely a coincidence
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post #9 of 28 Old 12-06-2018, 03:26 AM Thread Starter
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Thank you for the advice.


I am working on this as I find a spare hour here and there. I got things ready to take off the clutch side tomorrow evening. Will post an update when I see what that looks like.


If that doesnt pan out... I'll have to figure out how far down the rabbit hole I want to go. I've rebuilt alot of engines but I've always drawn the line at trannys. Tooooooooo many small parts lol. Splitting the case makes me mighty nervous. LOL




-DallanC
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post #10 of 28 Old 12-06-2018, 01:54 PM
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I understand - I am replacing a broken mainshaft in a CR80 at the moment - it broke the crankcase half behind the clutch where the bearing supports the shaft - I think I can fix it for less than $1000 - found a used clutch basket for $50 (OEM is almost $220) and a new case half for $120 - it didn't damage any tranny parts other than a snap ring - the only reason the clutch basket needs replaced is because the gear climbed the pinion and broke some teeth

Where do you hail from? I'm in Central Illinois USA - our temps here are in lower 30 to mid 40's and we are below average this year - we had 6 inches of snow in Nov and an outbreak of tornadoes on Dec. 1 (27 - a new record for Dec, but only third largest outbreak - largest outbreak was over 30 in 1958 and second largest was in 2006 - both 1958 and 2006 were in the spring) - historically we have had tornadoes in every month of the year

I have a waste oil furnace in my garage - it's "free" heat, but high maintenance - waste oil is dirty and the burn chamber has to be vacuumed out each year - takes the biggest part of a day to disassemble, clean, reseal and reassemble and it's noisy, but I don't have to pay a fuel bill to keep my garage 65 to 68 degrees all winter long - I also have gas heat, but it rarely runs - I got to have heat as I have a bathroom in my garage

Let me know what you find wrong as you progress with this project - you might want to cure the spark issue before working on the shifting issue
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