94 TRX300FW Complete Case Swap - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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post #1 of 14 (permalink) Old 06-18-2019, 10:59 PM Thread Starter
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94 TRX300FW Complete Case Swap

So as most of you know from my other post on the ol 300 I was having a power issue with and got that figured out, now I have a cracked case half and have to pull the motor and put everything in new cases, reinstall and put humpty dumpty back together again. I was asked to start another thread vs adding to my other so here goes.
I got a decent start late this afternoon and all I lack is pulling the starter, crankcase vent lines, bust the swingarm loose and the bottom engine mount bolts and she'll be on the table. So about a half hour or so tomorrow and I'll have her out and start stripping her down, just didn't have enough left in me to get it all out this evening lol. Getting the transfer case out was a tad of a bear but if ya hold your mouth just right and call it a certain name or two it'll come right out 😁! Here's a few progress pics so far from this evening.
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post #2 of 14 (permalink) Old 06-19-2019, 06:14 AM
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Looking at the pics , there seems to be a ring groove cut into the front drive shaft , if it grabs your finger nail when ran across then it is not going to last ---I would do one of three things , replace the drive shaft so it will hold oil and keep water and dirt out , install a 4x2 kick out at this time , or use the same shaft and pump the front diff and transfer case with water resistant grease
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post #3 of 14 (permalink) Old 06-19-2019, 03:00 PM Thread Starter
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I noticed that when I got it out but it's smooth as a baby's butt I promise, absolutely nothing there on both ends. I've got new seals for it when I ordered all the other seals and gaskets since the ones in it seem to be a little wet around them and starting to collect dirt and get that buildup started on the case. No sense in having it sitting in the floor and not spend 24 bucks and a little time changing them out. I appreciate the heads up and keen eye Fish, glad you're here and aware of my little project lol. Any words of advice when I get her opened up and start gutting it and putting everything in the new cases, things to be aware of, anything to pay more attention than normal or anything since you've done several of these.
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post #4 of 14 (permalink) Old 06-20-2019, 11:01 PM Thread Starter
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Alright, got her out! Took the new used cases outside and used dawn and baking soda with a toothbrush and detail brushes and removed all the bearings and O rings left in them, old gaskets removed, blown out and ready to go. Wrapped em up and set them to the side and started the teardown. Got the top end off and started on the right side case. Everything was rolling right along until I went to remove the clutch basket. I remembered it as soon as the case was removed and I took the bearing out and saw the nut. It had "been previously molested" when I got it and someone almost destroyed the nut and when I built it originally, I had a hard time getting it off, a real hard time. I fooled with it for almost an hour with zero success so figured I'd call it a night and start fresh tomorrow. Needless to say, I didn't get done what I intended tonight dangit. I did however get some pics lol.
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post #5 of 14 (permalink) Old 06-21-2019, 10:03 PM Thread Starter
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Back out in the shop this afternoon before the next kick in the nads hit lol. Got the nut off the crank and removed the clutch basket after about an hour and 20 minutes of trying everything, and last but not least....the Dremel! Cut a slit and careful not to get into anything other than the nut, then a few smacks with a drift punch and a dead blow and voila! Ordered 2 each from Partzilla for it and the centrifugal clutch also, so new going back on and a pair in the hole! Got everything out of the right side and almost everything out of the right until it came time to use the puller and that's when it snapped, dead in the water! So, I called it a day, mixed a stiff drink and going to watch Battle Bots and listen to the thunder and rain till bedtime lol. So stinking close to splitting cases and starting to put things in the new ones, really bummed me out, but se lave'!!! A few more progress pics for y'all. My little girl heard my vocalization when I broke my puller and had to come see what was going on with dad, had to add that pic in of the nosey little brat! 😁
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post #6 of 14 (permalink) Old 06-23-2019, 09:23 PM
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Looking good , you got it clean ----so you going to put a fresh jug and rework the head while it is down ? G+H is a good source for a bore and parts
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post #7 of 14 (permalink) Old 06-24-2019, 12:19 AM Thread Starter
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Hey Fish! No man, all that's brand new from when I did everything when I got it and bet theres not 35 hours on it. G&H did the bore and hone, complete head job (I sent new Honda valves, seals, guides and springs) and i put all new rockers and everything in the box, new cam, chain, sprocket, Namura piston and rings from G&H with the oversized bore. Everything looks amazing so i luckily don't have to fork out that junk of cash all over again. I'm going in the morning and picking up a 20mm x 1.5mm left hand thread bolt from a fastener company (Fastenall) to pull the flywheel. I was trying a different puller, that I read later shouldn't have been, that broke. I'm lucky it broke and not my flywheel so I got lucky for a change. The puller as you're aware of is nothing but a bolt so why spend 30 bucks on one I can get for 4 or 5 bucks that does exactly the same thing and not have to wait on shipping. I found one under 20 bucks from Motion Pro on fleabay, but back to the shipping thing, not waiting. My goal is to have this thing in the new cases, all put back together and at minimum in the bike and all hooked up or dang close to it by Friday and giving it a test ride Saturday or Sunday. Hopefully it won't take that long but I don't have endless time to be able to stay in the shop for 8 to 10 hours for a few days to do it, so a couple hours here and there and I should be able to hit my goal. Slow and steady wins the race. I'll be back out there tomorrow moving forward so I'll post a few more pics with an update tomorrow evening.
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post #8 of 14 (permalink) Old 06-24-2019, 04:57 AM
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Sounds like you got it going on ------- I am not a fan of Fastenal , around here they make you buy the whole bag or box and you wind up with a lot of waste ------then without an account they make you buy $50 min
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post #9 of 14 (permalink) Old 06-24-2019, 08:36 AM
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Sounds like you got it going on ------- I am not a fan of Fastenal , around here they make you buy the whole bag or box and you wind up with a lot of waste ------then without an account they make you buy $50 min

Same here, could've had a whole box of puller bolts for $20, but they had to order them.
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post #10 of 14 (permalink) Old 06-24-2019, 01:35 PM
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Looking good. Dang those cases are clean! The ones your replacing and the new ones both!

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