92' TRX300 Shifting w/ Stator cover off

Ok further info, further frustrations.


I removed the clutch cover, kick start, reverse lever, and clutch linkage. Shifter works flawlessly up and down the range, including reverse. I installed the reverse lock lever, it shifts through the entire range, stopping in neutral as expected. I manually turned the reverse lever and it dropped it reverse, then I shifted back up into neutral.


So far so good. I then replaced the clutch linkage and retested shifting, all worked as expected. I then replaced the kickstart, gasket and put the cover back on tapping it by hand and then slightly snugged it up with a few screws. I tried shifting and it went up through the gears but not down. Seemed the same binding. I removed the cover and it again shifted fine. I double checked the reverse lock was installed properly (IDK how someone could even mess that up, it only goes on one way with the spring) and not binding. It moved freely and easily.



Maybe the clutch linkage isnt seating in properly with the 3 ball thrust bearing against the case side? I'm really frustrated at this point... and actually a bit more than frustrated as I jumped the Neutral wire to ground and tried testing for spark by turning it over... still no spark.


So the pickup coil was not problem, which means I never had to remove the covers and go down this other frustrating path. Ugh... IDK what to do at this point. I've had the clutch cover off and on 4 times or so tonight. I think its all lined up and on correctly and then I test shifting and its binding up. So I at least know its the clutch side... and I dont think its the reverse lock.... which only leaves the clutch linkage.


Wish you lived closer! I'd drop it off with a pile of $$$ to get it going lolz



-DallanC

Ok so victory!

I have all the components in, the clutch cover on and snugged up (will torque it later), it shifts fine up and down the gears and into neutral.

What I think happened was when the stator cover came off, the shift shaft pulled out just far enough it didnt engage the stops. Then when it got shifted, it over rotated causing the clutch assembly to come discombobulated. Later when I reassembled the clutch side, I think it was the angle I was working from... it appeared the dot and > case mark were aligned but was still off one tooth. This caused it to rotate one way but bind going the other.

So, you were absolutely correct in that it was something simple and overlooked. I'm just glad nothing was broken or bent.

I took a quick try on the spark issue. I threw on the newer CDI to replace the new CDI that replaced the oem, nada. So I'm back to chasing the spark issue, but I'll go look through the plethora of other spark related threads.

This thread can be considered Solved / Fixed. And a major hearty thanks for taking the time to give advice!



-DallanC