My TRX 250r is burning transmission oil from somewhere really bad. First of all, does anyone have an idea where this oil may be burning from? If you need more details refer to my post "Please Help 2" in perf. mods and mechanical.
Also, I called three local shops today to see what they would charge to take it apart and see whats wrong, it ranged from 400-750 just for labor, and that didnt include parts!
I do most of my own work, and the only reason I didnt wanna do this, is cause I dont want o mess with it. But I wil for 400 bucks for sure, so, how hard is this to do? Should I just replace all gaskets and seals and hope that fixes it? How much is a gasket/seal set for the lower end?
Thanks

 

you can buy a complete gasket set for around $50-60. not sure how much bottom end is alone though

 

I think that anyone with some mechanical knowledge can work on the 250R. You will need 3 key thing to succeed a shop manual for the R's, a clean quiet work environment, and some patience and attention to detail.

I split the cases on an R when I was like 16 we went completely through the tranny and replaced like every bearing in the machine. If you just take your time and follow the shop manual you can easily work on the R's. In my opinion there was nothing particularly tricky about the project.

Adam Smith

99 400EX

 

Hey Rhino99;
Sounds like you found the problem. I just shattered second gear on mine and it came through the case, putting to huge holes in it. Spliting the cases will require a flywheel puller. I attempted this, but don't have a flywheel puller. Read through the manual and you will see what I am talking about. It sounds like your crank seals are gone ($20) and while you have it down, you should change crank bearings if it has never been done ($30 a piece). Also, thank about changing second gear (usually breaks on 86, 87).

I think I am pretty mechanically inclinded, but when I attempted it I thought, no way...i'll take it to someone who knows what they are doing. But I talked to a shop today and saw two cases abart and he said $400 - 900 for mine depending on what shattered. Seeing them apart, it didn't look too bad...I now have renewed spirit and not very much cash. I am going to try it.

Do you ride at Attica at all?
Nick

 

400 to 750 dollars is outrageous, I do work on all types of ATVs and I only get 200 for splitting the cases on a 250R. If your willing to ship that thing to Arizona count on spending 200 labor plus parts and also if your interested I do port work for any type of riding.

 

Splitting the cases on a 250R is not too difficult AS LONG AS YOU HAVE THE CORRECT TOOLS! I have seen and heard of a lot of people that have tried to do this with the wrong tools and have ended up ruining $275 case assemblies! Anyway, as far as burning tranny oil, your right main seal is the culprit. I have never replaced one without splitting the cases first. Actually, you can get to it without splitting the cases, but I don't think that you could remove it because the crank would be in the way. Anyway, I would love to help you out, I can't believe that shops charge $900 to split the cases. That is totally outrageous. I would do it for $100, but of course you would have to buy all the parts. Main bearings are probably between $20-$30, seals are around $17, a gasket kit is about $50(complete engine gasket kit). Heck, for $900 I could almost build you a brand new bottom end! Let me know if I can help.

 

Hey guys, thanks a lot.
The real cool part is my shop told me they replaced this. I am going to replace it and then take it back and tell them what the deal is!

Raychalp, thanks for the offer, if I get it apart and dont think I can manage, I will be happy to send it to you. Also, I was going to e-mail you about the parts you had for sale on the 250r forum, could you send me a list of top ends that you have for sale please?
Everyone else, thanks so much for the help, I really appreciate it!
Adams44, I have never ridden at Attica. I have friends who go there all them time, but I HATE climbing hills, some bad experiences riding a 300ex. The first day that I got it, I went riding with these guys on some hills and stuff and they got me into this place where no matter what I had to climb a big hill to get out. I had never climbed a hill before except on a 300 4X4, which isnt real hard, anyway, I go shooting up this hill and stall at the top, fly back down it backwards and hit a tree with my grabbar. Bust that, they make me try it again, this time, I fly off the top straight into a tree, busted my brand new AC front bumper. Then we gotta climb another smaller but washed out hill and I ended up flipping about 3 times on my way down!
So...I dont like it much. But I plan to go with them sometime and hopefully conquer my fear now that I can ride way better than I could then.

 

Unless the shop is doing it cheap for you, do it your self. The hardest part is removing with a 27mm socket. the clutch basket. Use a pneumatic impact wrench. I did this to my 86 and it was easy. Take a punch and make a small hole in the seal. Then screw in a sheet metal screw anout 1/8" and pull the seal out with a pliers. Any questions, ask. I'll be happy to go throught the process with you. A clymer manual is a must!
ERIC