adam 15 Posted May 7, 2023 Hey guys, Adam here from Australia! Hope you're all well :) A few years ago I purchased a 2000 TRX350 FE ES with a bit of shift issue - well, I'm sure you've heard the rest a thousand times before! To say it had a rough life is an understatement. Working my way through the repair manual, I eventually found the culprit. Basically the last piece to be pulled from the entire machine - the shift drum - with its shaft broken off. I have ordered a new one from a 2002 model with the larger shaft, to be sent from Japan in the next month hopefully! In the process of dismantling I decided to rebuild the thing completely and replace any dodgy parts that needed replacing. I removed rust from the frame and resprayed it and will do the same to the other metal components. I've replaced the angle sensor, oil temp sensor, and gear position switch. The case is in bits and that's why I'm here! I've found some really insightful threads from some very knowledgeable people on this site and no doubt I'll need to tap into that. Wish me luck on this journey guys! Cheers, Adam 4 Share this post Link to post Share on other sites
bcsman 1,404 Posted May 8, 2023 Hey Adam, welcome to you. You have sent this from a long ways away, down under, bet it took a few days to get here.....lol You certainly have it stripped down, there are numerous members here that have the TRX 350's. I'll bet you get some good advice if you need it. Heading into winter down there huh, just finally getting warm up here...... 2 Share this post Link to post Share on other sites
_Wilson_™ 6,591 Posted May 8, 2023 Hi Adam, welcome to the forums (waving a hand from across the pond) 1 Share this post Link to post Share on other sites
adam 15 Posted May 8, 2023 26 minutes ago, bcsman said: Hey Adam, welcome to you. You have sent this from a long ways away, down under, bet it took a few days to get here.....lol You certainly have it stripped down, there are numerous members here that have the TRX 350's. I'll bet you get some good advice if you need it. Heading into winter down there huh, just finally getting warm up here...... Thanks mate - yep starting to cool down a bit - especially where I am! 1 Share this post Link to post Share on other sites
adam 15 Posted May 8, 2023 22 minutes ago, _Wilson_™ said: Hi Adam, welcome to the forums (waving a hand from across the pond) Thanks mate - good to be here! 1 Share this post Link to post Share on other sites
bcsman 1,404 Posted May 8, 2023 How hard is getting parts over there, some older models are getting tough here in the states? Share this post Link to post Share on other sites
adam 15 Posted May 8, 2023 4 minutes ago, bcsman said: How hard is getting parts over there, some older models are getting tough here in the states? I had sources for the shift drum about a year ago (Partzilla and a couple other online suppliers) however I didn't have the funds at the time and they sold out. I was close to buying a used one from a 2000 model from a wrecker (salvage) but reeeeeeaaaallly didn't want to put a used one in not knowing the history, etc.. I found a Japanese OEM supplier (yumbo) and ordered one through them. Hopefully I don't get ripped off and they send the part. It set me back about $150AU so if it comes it's definitely good value. Parts in Australia are difficult to come buy for these bikes. They have all dried up in the used market. 3 Share this post Link to post Share on other sites
bcsman 1,404 Posted May 8, 2023 Same here, sometimes get lucky on Ebay but have to be careful it's not a China knockoff part. Here is a used ATV parts site alot of guys here check out, mostly used.... https://www.powersportsnation.com/ Share this post Link to post Share on other sites
adam 15 Posted May 8, 2023 Just now, bcsman said: Same here, sometimes get lucky on Ebay but have to be careful it's not a China knockoff part. 100% I really don't want to have to split the case again after this! Share this post Link to post Share on other sites
bcsman 1,404 Posted May 8, 2023 Check out the link I posted, not sure what they would charge to ship your way tho..... Share this post Link to post Share on other sites
adam 15 Posted May 8, 2023 Sorry, where do I find the link mate? Share this post Link to post Share on other sites
bcsman 1,404 Posted May 8, 2023 4 posts ^^^^^ I edited to add it... 1 Share this post Link to post Share on other sites
Fishfiles 20,147 Posted May 8, 2023 Welcome toATVHonda. Retro’s thread on ES preventative maintainance is something you should read thru. And Retro’s Cremesickle 350 thread would be another good read where in Australia do you call home. Always wanted to do a walk about down under. 2 Share this post Link to post Share on other sites
jeepwm69 7,719 Posted May 8, 2023 I rebuilt a 2005 for my middle kid. I had an extra 2000 350 engine that I actually used, and while I had it apart I replaced that early shift drum with the later part. Have to knock out that needle bearing that supports the rear in order to put in the newer part, but she hasn't had any problems with it since I put it back together. Been a neat little nimble machine. I actually like riding it better than I do my 500's. 1 Share this post Link to post Share on other sites
adam 15 Posted May 9, 2023 19 hours ago, Fishfiles said: where in Australia do you call home. Always wanted to do a walk about down under. Thanks for the tips! I'm in Bremer Bay on the south coast of Western Australia. Probably about as far away from anywhere else in the world! 1 Share this post Link to post Share on other sites
adam 15 Posted May 9, 2023 15 hours ago, jeepwm69 said: I rebuilt a 2005 for my middle kid. I had an extra 2000 350 engine that I actually used, and while I had it apart I replaced that early shift drum with the later part. Have to knock out that needle bearing that supports the rear in order to put in the newer part, but she hasn't had any problems with it since I put it back together. Been a neat little nimble machine. I actually like riding it better than I do my 500's. It was great fun when it was running. Loads of power! Great for the beaches down here. Share this post Link to post Share on other sites
adam 15 Posted May 10, 2023 Hey guys, I need a new manual shift shaft - can someone please confirm the part required? I think it might be 24611-HN5-A10 but not 100% sure... To be clear it's the shaft used to shift the box when the ES is not working/flat battery, etc.. You use the tool provided. The previous owner welded a peg to it so it could be used to shift manually by foot. Seriously. Share this post Link to post Share on other sites
jeepwm69 7,719 Posted May 10, 2023 You are correct on the part number. Looks like it is discontinued though. https://www.partzilla.com/catalog/honda/atv/2005/trx350fe-a-fourtrax-rancher-4x4-es/gearshift-fork When I rebuilt my kid's 350ES I replaced that with a footshift shaft, which is splined on the end, and attached a factory footshifter to it. Then I removed the reduction gears under the ES shift motor and now the machine is a footshift. Point being, if you were to put a footshifter shaft on there, even if you continue to use it as an ES, you could then put a splined factory footshifter on it at any time if needed. Looks like shipping is going to maul you as all of the listings on ebay AU are shipping from the US. https://www.ebay.com.au/itm/124486896657?hash=item1cfbff4c11:g:ncoAAOSwzJZf18ni&amdata=enc%3AAQAIAAAA0HzTA1P94h9HT3zWkbZTG7BQbB2Nxej9xLhIJs2HGb3GNHUrJQa2BMIhIOOI%2F1s5hgzdIXQrFRk9fq3wFr6QVRP52MUBkTtonAjbyS18F32fm4cKNwxbQL2p4YYxNokF408U20sMwVcjX8RPUJG2%2Fa33uVnTxH%2BhPFIzNsJ%2BmZu4skfV4BHOEWAoZvFPm%2FmS7WIupiiTfSFRBawMZ5dIiudgA2b2wX3X8eKMlABO46JcHj8iD0VMyKxU96N4p12vxQkRfZTuX57N8zGjX1usfWA%3D|tkp%3ABk9SR_7Z8uCAYg 1 Share this post Link to post Share on other sites
THH 297 Posted May 10, 2023 Welcome and good luck with the rebuild! 1 Share this post Link to post Share on other sites
adam 15 Posted May 11, 2023 On 5/10/2023 at 10:30 PM, jeepwm69 said: Point being, if you were to put a footshifter shaft on there, even if you continue to use it as an ES, you could then put a splined factory footshifter on it at any time if needed. Does shifting manually risk damaging the ES system? Share this post Link to post Share on other sites
jeepwm69 7,719 Posted May 12, 2023 On 5/11/2023 at 6:38 PM, adam said: Does shifting manually risk damaging the ES system? You’ll fight the shift motor, but otherwise no. The 350 transmissions are the same whether footshift or ES. I removed the gears under the shift motor on my kid’s 350ES, so now it drives and shifts exactly like a footshift Share this post Link to post Share on other sites
adam 15 Posted May 13, 2023 21 hours ago, jeepwm69 said: You’ll right the shift motor, but otherwise no. The 350 transmissions are the same whether footshift or ES. I removed the gears under the shift motor on my kid’s 350ES, so now it drives and shifts exactly like a footshift Yeah from the way I interpret the user manual, shifting with the manual over-ride will disable the ES system which can be reset by powering off and then on again. I'm just wondering what caused the shift drum shaft to snap off in the first place. They seem to have very little resistance against the shift sensor. Share this post Link to post Share on other sites
jeepwm69 7,719 Posted May 15, 2023 On 5/12/2023 at 8:35 PM, adam said: Yeah from the way I interpret the user manual, shifting with the manual over-ride will disable the ES system which can be reset by powering off and then on again. I'm just wondering what caused the shift drum shaft to snap off in the first place. They seem to have very little resistance against the shift sensor. Just a weak design. They were a known problem which is why Honda redesigned them in the newer 350's. Hondas are the best, but they do occasionally get it wrong in the first go round. At least when they upgrade a part it will usually swap right in. Share this post Link to post Share on other sites
adam 15 Posted May 18, 2023 https://quadbitz.co.nz/products/honda-trx300-shift-drum-forks Just found this - not far from me (only 5000km across the ditch!)... doesn't have the year but looks pretty close. What do you think? Share this post Link to post Share on other sites
jeepwm69 7,719 Posted May 18, 2023 23 minutes ago, adam said: https://quadbitz.co.nz/products/honda-trx300-shift-drum-forks Just found this - not far from me (only 5000km across the ditch!)... doesn't have the year but looks pretty close. What do you think? looks to be the newer style. pics of both styles in this post Share this post Link to post Share on other sites
