shadetree

here's how i do it, and you can check it if ya want ?. first, i pull the spark plug, then i pull the pull starter off the back, under it, is the pull rope cage, on one of those '' tangs '' is a line, this line runs from the front of the tang, to the back towards the engine case. if you look right above and behind that line, there is a triangle , it points down, this triangle lines up with the line on the tang. back at the front, behind the clutch cover, up in left hand corner, is your cam, above the sprocket is another triangle, this is your index, on the cam sprocket is a punch mark, this punch mark lines up with the index at the very top. if none of this lines up right ?, it makes me wonder if the PO turned the cam sprocket 180 out , and bolted it back on the cam ?. make sense ?.

replace both clutch parts !, the housing is burnt, just clean it off with a wire brush. soak both clutches in the correct motor oil a bit BEFORE you install them if you get new parts.

did you adjust the clutch after you installed new disk ?, you must adjust the clutch every time you install new disk !. also its best to soak the disk in engine oil a good bit BEFORE you install them.

my last post ^^^, if the timing marks show to be on the exhaust stroke, and not the compression stroke ?, well..there is one of your problems right there !.

very important !!!. you say you believe the timing is correct when you looked at the marks and index ?, my question to you is, was the timing marks checked when the piston was on top dead center on the COMPRESSION STROKE ?, AND NOT THE EXHAUST STROKE ?.

versha engine gasket kits, or namura complete engine gasket kits, complete engine oil seal kit should get you started. my first plan of attack would be : see if the timing is indeed correct ?. pull the head off, remove the valves, run them in a drill, watch to see if they wobble ?. if they do ?, they are bent. as for cam chains ?, i run nothing but D.I.D. brand. deff give the carb an over haul, shindy carb rebuild kits is all i use in my carb over hauls. you will need a clutch puller tool if you plan on splitting the cases ?. if your not gonna split the cases ?, no need in buying a complete engine gasket kit. if you do find out your rod is bad ?, then yes, you will need a complete engine gasket kit. BE SURE TO CHECK YOUR ROD FOR PLAY AT BOTH THE TOP AND BOTTOM !!!. exhausting out the carb tells me the timing is off ?, or a bent/bad valve ?. keep us informed , lots of us know this model inside and out !..lol.

welcome to the forums

is there a reason your running a trx300ex carb instead of the correct carb ?, i really dont think the trx300fw will run very well with that trx300ex carb..this will be interesting to see how this turns out !..lol.

ummm..may i ask what carb is hanging down in this pic ??..CUZ IT SURE AS HECK AINT A TRX300FW CARB !.

good deal !.

one in stock at rocky mountain atv, you better buy it before its gone !..lol.

keep us updated on how long the rear drive line holds up please !...lol.

i can tell you right now, the 1988 trx300fw is a ONE year only c.d.i. !!. no other years will work on it.

NOPE, HE GOT IT CORRECT NOW !..LOL. i may forget alot of things ?, but the one thing i do know ?..is the timing marks must be dead on ?!!, if they are not ?, then something is not right !.

NOW THAT IS CORRECT !!!, YOU CAN'T GET ANY BETTER THAN THAT BRO !, WELL DONE !.

update: as you can see from the following pic's, i'm making progress !. it's slowly coming together, but dang...cleaning piece by piece, then painting it ( if it needs it ? ) is making this old man starting to get burn out fast !..lol. the good news about this build ?, is the man that bought the '88 trx350D said he will buy this when its done ?!..lol.

looked again at the pic with the T mark, the index looks like its on top of the T ?, where this is not where you put the index mark at, it should be sitting over the line !.

if a new cam chain was installed ? ( did not back read ! ), and your marks are where you think they should be ?, then this tells me the crank teeth are worn down.

then your doing something wrong !..lol. every engine build i have ever done in my years, every one of them lined up dead on !.

timing is off a tad.

lol, the left side was already * gone * ?..lol, all that was left on this bike was the right side, i said..wtf cat fish, what good is the right side if the left side is already gone ?, he bowed out, gave it to me for this '87 build..rofl.

yeah, that is the fuse tray cover, it does show, but come on, its mostly covered when the seat it on, and its never opened for the most part, just paint it blue. you've been doing this a long time ( and you do know your stuff ! ), but some times when parts are discontinued ?, you have to bite the bullet, and make do !. i'll look around, and see if i can find ya one, if i do ?, i can tell you right now..with it being blue ?, IT WONT BE CHEAP !..LOL.

haha..i don't have any blue covers..and if i did ?, i WOULD NOT LET GO OF IT...NO MATTER HOW MUCH YOU BEGGED !!..LOL. i was lucky enough to snag a red right side cover from cat fish..and he knows what they are worth !, i got it free ( nice to have friends in low places huh ?! )..lol.

just paint the red part blue, it does not show if its inside the tool box when closed.

agreed bro !. i cant count on all my toes and fingers how many times i have to try to remember all the different parts on these models, years ?!..lol.