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jeepwm69

Sideways engine case splitting (TRX300FW)

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Yeah, I could call @shadetree, but figured a post instead might be good reference material for future folks looking for info.

 

I’ve done a lot of front-to-back engines (05-11 500’s, 420’s, 350 Ranchers, 400/450 Foremans) but I tore down a 300 today and they seem a little more different when it comes time to actually split the cases, and typical me, did the same screw up I did last time.


For the second time in a row, I tried pulling the shift drum linkage side off the other (shift mech is on the front/ clutch side on the front-to-back engines), only to discover that the shaft from the output housing pulls out of the transmission, which I’m assuming means when I split cases in the future I need to remove the cup from the other end of the shift drum and pull the clutch (front) side off leaving the transmission gears in the other side.

 

That sound right?

 

I split an extra engine I had today to get a better look at how I might get the kick start washer out of the one I’ve been working on (Still don’t see any way to get it out without splitting cases).

 

It had about 1.5 inches of mud and gravel in the bottom of the cases…lol

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50 minutes ago, jeepwm69 said:

Yeah, I could call @shadetree, but figured a post instead might be good reference material for future folks looking for info.

 

I’ve done a lot of front-to-back engines (05-11 500’s, 420’s, 350 Ranchers, 400/450 Foremans) but I tore down a 300 today and they seem a little more different when it comes time to actually split the cases, and typical me, did the same screw up I did last time.


For the second time in a row, I tried pulling the shift drum linkage side off the other (shift mech is on the front/ clutch side on the front-to-back engines), only to discover that the shaft from the output housing pulls out of the transmission, which I’m assuming means when I split cases in the future I need to remove the cup from the other end of the shift drum and pull the clutch (front) side off leaving the transmission gears in the other side.

 

That sound right?

 

I split an extra engine I had today to get a better look at how I might get the kick start washer out of the one I’ve been working on (Still don’t see any way to get it out without splitting cases).

 

It had about 1.5 inches of mud and gravel in the bottom of the cases…lol

you can use a dremel to widen the lower hole to get to the washer, but by doing this..you must rinse the cases out very well from all the alum shavings. as for which side to lay the 300 engine down when splitting the cases ?, left side goes down, ( stator side ). always have the centrifugal clutch facing at the very top. new engines like the 350 rancher, 400, 420. 450. 500..all of these must have the front clutch cover at the top, stator side ( rear ) on the bottom. yer welcome..lol.

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Something they did on the 400ex engine cases i thought was very smart is they have 9 or 10 of the case half bolts you take out from one side. You remove those first. Then you flip it over and there are 2 more from the opposite side. It keeps the case halves together. And reminds you which side to have facing up. Dont know if they did this on the utility quad engines or just sport quads. But i know for sure the 300ex was that way and 250x aswell.

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31 minutes ago, SlammedRanger said:

Something they did on the 400ex engine cases i thought was very smart is they have 9 or 10 of the case half bolts you take out from one side. You remove those first. Then you flip it over and there are 2 more from the opposite side. It keeps the case halves together. And reminds you which side to have facing up. Dont know if they did this on the utility quad engines or just sport quads. But i know for sure the 300ex was that way and 250x aswell.

The TRX300 4wd and 2wd and the TRX450FM ,  S  , ES and FE are also made like that 

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2 hours ago, SlammedRanger said:

Something they did on the 400ex engine cases i thought was very smart is they have 9 or 10 of the case half bolts you take out from one side. You remove those first. Then you flip it over and there are 2 more from the opposite side. It keeps the case halves together. And reminds you which side to have facing up. Dont know if they did this on the utility quad engines or just sport quads. But i know for sure the 300ex was that way and 250x aswell.

Yep, almost all of them

have 8-10 on one side and 3 on the other.  That’s a good tip

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HI: This may help -- Cut a V notch see picture

Honda washerremoval.jpg

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52 minutes ago, Melatv said:

HI: This may help -- Cut a V notch see picture

Honda washerremoval.jpg

I’m thinking if I stuff a blue shop towel up in there and then cut it out with a Dremel I should be able to suck the chips out since the blue shop towel will keep them from going all up in the engine

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Finally got my butt out of bed early (been lazy lately) and did some clean-up work in the shop.

 

I'm waiting on a gasket set for my buddy's 450 Foreman, so I went to work on the 300 cases on the engine I tore down last weekend.  I HATE SCRAPING GASKETS!

 

Got the center cases cleaned up on both sides.  Crank was bad on this one, but have a good crank on the shelf I got from PSN at some point, so will press it in in the next day or two and see if I can get the transmission back in without screwing something up.

 

Waiting on a gasket set for this one too, so wont' be able to go past setting the transmission in there.

 

Question.....When I put the shift drum in the "back" (left side) the bearing tries to fall out and drops the shift drum down.  Is there a trick to keeping that in place while putting the transmission in, or do I just have to improvise?

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1 hour ago, jeepwm69 said:

Finally got my butt out of bed early (been lazy lately) and did some clean-up work in the shop.

 

I'm waiting on a gasket set for my buddy's 450 Foreman, so I went to work on the 300 cases on the engine I tore down last weekend.  I HATE SCRAPING GASKETS!

 

Got the center cases cleaned up on both sides.  Crank was bad on this one, but have a good crank on the shelf I got from PSN at some point, so will press it in in the next day or two and see if I can get the transmission back in without screwing something up.

 

Waiting on a gasket set for this one too, so wont' be able to go past setting the transmission in there.

 

Question.....When I put the shift drum in the "back" (left side) the bearing tries to fall out and drops the shift drum down.  Is there a trick to keeping that in place while putting the transmission in, or do I just have to improvise?

 

1 hour ago, jeepwm69 said:

Finally got my butt out of bed early (been lazy lately) and did some clean-up work in the shop.

 

I'm waiting on a gasket set for my buddy's 450 Foreman, so I went to work on the 300 cases on the engine I tore down last weekend.  I HATE SCRAPING GASKETS!

 

Got the center cases cleaned up on both sides.  Crank was bad on this one, but have a good crank on the shelf I got from PSN at some point, so will press it in in the next day or two and see if I can get the transmission back in without screwing something up.

 

Waiting on a gasket set for this one too, so wont' be able to go past setting the transmission in there.

 

Question.....When I put the shift drum in the "back" (left side) the bearing tries to fall out and drops the shift drum down.  Is there a trick to keeping that in place while putting the transmission in, or do I just have to improvise?

if this shift drum is for the trx300fw ?, the trick is to install the outer brackets that hold the bearing in, two dowls, metal plate i think it is ?, this keeps the shift drum in until you work that left side.

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Looks like I'm not the only one who has struggled with that shift drum.

 

Pretty good video here on a full reassembly of the 300 engine.   Not so sure about using gaskets AND Hondabond, but guess it couldn't hurt.....

 

 

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Got this one back together this morning.

 

Waiting on gaskets for this one and my buddy’s 450 now.


Timing marks in the first pic

 

@shadetree’s suggestion on putting the bearing plates/dowels/shift plate in place to hold the shift drum bearing in place worked like a charm

 

2C04E2DC-510A-476D-A346-08F34F7955C4.jpeg

2431488B-BE50-4FDE-A6F8-9CCDEEC04BAA.jpeg

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1 hour ago, jeepwm69 said:

Got this one back together this morning.

 

Waiting on gaskets for this one and my buddy’s 450 now.


Timing marks in the first pic

 

@shadetree’s suggestion on putting the bearing plates/dowels/shift plate in place to hold the shift drum bearing in place worked like a charm

 

2C04E2DC-510A-476D-A346-08F34F7955C4.jpeg

2431488B-BE50-4FDE-A6F8-9CCDEEC04BAA.jpeg

would i steer you wrong on an engine build ?..lol. glad it worked out for ya bro !!. i've got a mess on my hands again with this other 450 engine, but i'll get-r-done !..lol.

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