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I removed the outer gear case not realizing that the transmission output shaft was part of it. When I try to get it back together I can get it to about 1/2" from being all the way in but it just won't go. I removed the right side outer case to expose the kick starter gear and where the shaft comes threw the other side but still no luck. Does anybody know a trick to getting this in? If someone had a few pages of the trans section of a manual that would be great since I have not been very successful in finding a manual either. Any help would be great.
 

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This is something i know little about, only advise i got is to check you splines and make sure there are no retainerclips left on also look at any locator pins to make sure there sliding the two cases correctly togather. GL and let us know how it goes

p.s picutes may help
 

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I don't have a manual for the Fourtrax 250, but I have one for a Fourtrax 300. I was thinking the bottom of those engines are about the same, but I'm not positive as it's been a long time since I worked on a Fourtrax 250.
 

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Hey Helmut I have the same problem but I do have a Fourtrax 300 I can get it almost all the way in but it seems to be getting stuck on something towards the end. Should the shaft just slide back in there or am I missing something ??
 

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Hey Helmut I have the same problem but I do have a Fourtrax 300 I can get it almost all the way in but it seems to be getting stuck on something towards the end. Should the shaft just slide back in there or am I missing something ??
Welcome to the forums. If you pulled the output shaft out, you will have to split the crankcase to get it back in. When you pull the shaft out, the gears come off and drop down. It would have been nice if Honda would have put a warning sticker on there saying that, as I'm sure a lot of people have pulled that out unaware of that happening.
 

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Were Honda to warn people,or add a c clip to hold the gear on they wouldn't be able to sell new gaskets,or charge the hours,and shop supplies to reinstall said output shaft,and side cover properly to those who inadvertently remove the cover with the shaft hung up in it....
 
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