[Newb]

I have an '04 Recon 250TM, just bought used for Christmas. Has been difficult to shift, and today I looked down and the shifter was up around the 10-11 clock position. Was able to shift it down to neutral. I noticed the gearshift spindle (what the foot lever attaches too and goes into the case) slid in and out. I tried to adjust it and ended up pulling it out. It leaks oil from that hole, and when I try to push the gearshift spindle back in it will only go about an inch (needs to go 2-3 inches). The spindle on it looks good. When I look in the hole it came from I can see what appears to be a triangular shaped "receiver" spindle that is offset, which I am guessing is why I can't push it back in. Any ideas on what I need to do to fix this? The manual doesn't seem clear on this to me. Seems to tell me to first take off the centrifugal clutch and clutch; also the alternator cover. I am hoping to not take anything off, but at most the alternator cover? looking at Ch9 of the TRX250TRM 1997-2004 Service manual, but I am NOT a mechanic.

 

[GirlsRideToo]

I have an '04 Recon 250TM, just bought used for Christmas. Has been difficult to shift, and today I looked down and the shifter was up around the 10-11 clock position. Was able to shift it down to neutral. I noticed the gearshift spindle (what the foot lever attaches too and goes into the case) slid in and out. I tried to adjust it and ended up pulling it out. It leaks oil from that hole, and when I try to push the gearshift spindle back in it will only go about an inch (needs to go 2-3 inches). The spindle on it looks good. When I look in the hole it came from I can see what appears to be a triangular shaped "receiver" spindle that is offset, which I am guessing is why I can't push it back in. Any ideas on what I need to do to fix this? The manual doesn't seem clear on this to me. Seems to tell me to first take off the centrifugal clutch and clutch; also the alternator cover. I am hoping to not take anything off, but at most the alternator cover? looking at Ch9 of the TRX250TRM 1997-2004 Service manual, but I am NOT a mechanic.

Newb, you have arrived at the forum when all the experts are out drinking eggnog and I'm not sure when they'll be back. You are left with only me to answer your question. I'll do my best.

I have the manual you referenced. On page 9-2 you will see that the gearshift spindle slides into the gearshift A arm and is held in place by a lock washer and bolt. If the bolt is in place you should not be able to pull the spindle out. That tells me you have lost a bolt. It either backed out or broke. You said the spindle looks good so it doesn't seem the spindle broke. The fix? Find the bolt and that means removing the front crankcase cover. I'll let the experts take it from here as to the exact procedure. I hope it's not too big a job for you. Good Luck.

 

[retro]

The spindle arm has come off. The bolt that secures the arm to the spindle has either loosened and fallen out, or the end of the bolt has broken off in the spindle. As you can see inside the shaded area in the 1st attachment, the arm, bolt & retainer, washer, and thrust plate have all fallen off behind the crankcase cover. The cover will have to be taken off and all of those parts will have to be fished out. All damaged/worn parts will have to be replaced.

See section 9 of the manual for starters, then read and follow the procedures pointed to the other relevant sections. You'll need a decent set of tools for this job... probably a puller too. If you don't feel comfortable working on it, I advise that you find someone very old... with a great reputation to fix it for you. That might be your greatest challenge.

Good luck and have fun!

EDIT: Nevermind my rant... @GirlsRideToo got ya covered nicely... and beat me at the keyboard! No eggnog here today GRT... lotsa coffee tho. The big meal put me to sleep.
Hope your day went well.

 

[Newb]

Thanks for the help. I think I am going to bring it to the shop. Wanted to make sure I'm not missing something easy. Wish I had discovered this forum BEFORE I bought the recon (wouldn't have bought that one). I'll report back with how it goes

 

[GirlsRideToo]

Thanks for the help. I think I am going to bring it to the shop. Wanted to make sure I'm not missing something easy. Wish I had discovered this forum BEFORE I bought the recon (wouldn't have bought that one). I'll report back with how it goes

That is probably your best option. It is a daunting task to work on the engine when you have no previous experience or the tools. I have a strict policy with myself to never remove any engine bolt. I'll tackle everything else.

I"m not sure how you would have discovered this problem before you bought the bike. I don't think I've ever seen a recommendation to yank on the gear shift spindle before you put your money down. LOL. From what I've read, it's not a very common problem.

I suffered from a serious case of buyer's remorse when I purchased a 2014 Rancher 450 a few months ago, so I understand why you are discouraged. Chin up! Have your mechanic check out the spindle problem and parts in this area while he has the engine open. I believe there is a rubber seal near the end of the spindle that prevents oil from leaking so this may be a simple fix. It's the labor cost in this case. Hopefully, you have a good independent shop in your area.

Again, stay positive. Problems outside the engine you can most likely fix yourself with the guidance of the guys here and following the manual. Please do keep us posted!

 

[Goober]

Everything that needs to be said has been. Yes take it to the shop and get estimate, then steel yourself matey. It might sting a bit.
You can learn about the quads and then later perhaps consider another while you enjoy this one.