Hi chaps, once again thanks for all your advice!
Right, I removed the side case, and seems that the spring isnt broken (although cant really tell if its weak) i made the mistake of not looking to see the position of the folk shape plate as you described Shadetree, so the gear shift spindle pulled out of its other end, I realise the it doesnt matter how the spindle goes back in because I can change the position of the pedal afterwards, but the plate is what I am now wandering! I put it back together one way and I'm not really sure whether is has helped because it seems to spring back better (although thats just by using my hand and rocking the back wheels, so not entirely sure yet) but I wandered if maybe someone had previously took it apart and put it back together wrongly and thats where my problem is.
Or is this just wishfull thinking? does anyone know where the plate should be positioned?
Many thanks all!
It DOES matter how the spindle or shift shaft goes in, because the other end of the shaft has splines on it that has to engage an internal clutch lever behind the right side cover. That internal clutch lever has a punch mark on it and the crankcase has an index mark on it. Those have to be lined up or the clutch lever will be out of time and will not engage and disengage the clutches correctly. If you pull that shift shaft out any at all, you will need to pull the right side cover off and put the internal clutch lever in time. Make sure you have the shift shaft in correctly and make sure you put the left side cover back on, before you pull the right side cover off. If you don't the shift shaft can move out of position. If it moves out of position you will have to pull the right cover back off again and redo it.
I've explained how this works in two other posts, recently. You can find them and read them and I explained how to fix this. The post might be titled Fourtrax 250 shifting problems or something to that effect. The Fourtrax 250 and the Fourtrax 300 both, work the same way. It's the same process to fix them.