need to replace starter for a 300ex atv. what exactly do i need to remove to get starter out? pulled 2 bolts but doesn't slide over far enough to pull the shaft out. any tips??

 

hotdog77 i have a Haynes Owners Workshop Manual that cover's the 1993 to 1999 Honda TRX300EX and the TRX400EX ATVs , even though you didn't state what year your 300EX is ; they should be the same or close to it !

There are Illistrations in the manual that show in detail how to remove the starter , but i don't have anyway of scanning the pics. for you ; but i'll try to explain and desribe them to you as best i can !

Starter motor - removal and installation

In the illistration for the starter motor mounting bolts it shows 2 bolts ( Which you have probally already removed these 2 bolts )
1. On the removal of the starter on the 300EX it say's to
disconnect the cable from the negative terminal of the battery.( Which i'm sure you have already done this Part ) !
2. On the TRX300EX models , remove the starter gear cover bolts , remove the starter gear cover and remove the cover dowel pins and gasket (see illustrations 22.1a and 22.1b) In illustration 22.1a it shows the location of the 6 bolts with a black plastic cover with 2 screws that hold the plastic cover to the Aluminum cover , you don't have to remove the plastic cover to remove the main cover !
In illustration 22.1b... it shows the 2 dowel pins and reduction gear , and states that the dowel pins and gears may come off with the cover or stay in the engine .
3. On the TRX300EX models , remove the starter reduction gear and shaft. illustructon 22.2 it shows the starter reduction gear and shaft , you must remove the reduction gear and shaft in order to remove the starter !
If the dowels and gears come off with the cover , just keep them together or make note of how they go back in the engines case !

And it doesn't state this in the Manual , but don't turn the crankshaft while the starter and reduction gears are removed ; because if there is a starter possioner on your model it could get it out of time !
But like i have stated the manual doesn't show or state that there is one , but just to play it safe don't turn the crankshaft with the starter or gears removed.

4. Pull back the rubber boot and remove the nut retaing the starter cable to the starter.
5. Step 5. is for the TRX400EX only.
6. Lift the outer end of the starter up a little bit and slide the starter out of the engine case. there's a Caution : note that states Don't drop or strike the starter or its magnets may be demagnetized , which will ruin it.
7. Inspect the O - ring on the end of the starter and replace it if nessary.
8. remove any corrosion or dirt from the mounting lugs on the starter and the mounting points on the crankcase.
9. Before installing the starter motor , apply a little engine oil to the O - ring . and Tighten the starter motor bolts securely.
10. Installation is otherwise the reverse of removal , with the following additions:
On the TRX300EX models , be sure to tighten the starter gear cover bolts to the torque listed in this Chapter's Specifications.
I've looked all through this manual for the torque spec.s of the starter motor bolt's and starter gear cover bolts with no result's !

But i have worked over 20 yrs. in the Small Engine Service And Repair Industry , and i've never had a problem torqueing any bolt or nut on any small aluminum engine ; i'm not suggesting anyone who has a good torque wrench from ignoring the proper torque spec.s if they have them !

Only that i use a 1/4 in socket and ratchet when torquing these fastners , and when i have to use a 3/4 inch ratchet and socket i only palm the ratchet when torquing these fastners ; and i've never broken or stripped anything on an aluminum engine !
However i have had to repair stripped thread's , and removed broken bolts from engine's brought to me for repair ; after someone had damaged them !

hotdog77 i hope this make's sense to you and it help's you remove your starter , my manual covers the TRX300EX and TRX400EX from the year's of 1993 to 1999 ; but they should be close to your year make and model !
I only wish i had a way to scan the illustrations in the manual and send them to you , but i don't have a scanner and i've never been able to post a picture on this site ; i don't even know how to copy and paste a url to a web site that i've heard so many people tell someone to do !
I guess i'm just pc illiterate , or just plain dumb when it come's to something's i've done before ; but have forgotten how i did it before ! Good luck and i hope this help's you remove your starter , and have a happy and safe holliday's this year ; and a happy new year to everyone on the forums !...............

Oh by the way i bought this Haynes manual for the 1993 to 1999 Honda TRX300EX and TRX400EX from the Auto Zone Parts Store , you could get one at Auto Zone ; and if they don't have one in stock they will order one for you if you ask !
I don't own a 300EX or 400EX i only bought the one i have when i was looking through the manuals at Auto Zone and i saw this one i have , just in case someone i ride with or someone on these forums need info on servicing and repair !.................

 

when replacing the starter do we have to oil the gears?

 

No, unless you have removed the oil already on them with solvent. I used to do lots of Fourtrax 300s and the gears were quite often covered in mayonnaise if the owner did short runs at slow speeds. This mayo tended to wreck the outrigger bearing for the starter shaft, so I sometimes oil that.