This past summer I replaced the entire shifter box assembly, replaced the tie-rod ends on the main shifting rod. (Never use hi). Replaced that darn aluminum shift arm on the trans a few times. Always have a spare. Adjusted the shifter rod at least once when I replace the shifter box.

On top of this we rebuilt the secondary clutch, replaced the drive belt, rebuilt the carb, changed the oil, etc, etc.

Here's the problem. When I first start out (cold machine) shifting into reverse works perfectly. As I continue to run and the machine gets up to temperature when I shift into reverse it shifts but the neutral indicator light comes on, not the yellow reverse indicator. This means if in reverse I do not have 4wd when the N light comes on.

I can get the yellow R indicator light to come on if I shift into reverse before the ATV actually stops rolling at least 80% of the time during this time.

With winter approaching and plowing season around the corner I'd like to get this problem resolved.

Thoughts, suggestions??

 

I agree on the shift box as having problems,but at 13 years old any mechanical device can cause problems by internal parts wear. Same for the linkage ball ends and aluminum belcranks on the gear case. The reason aluminum is used instead of steel is so that they CAN strip rather than tear up the shift mechanism in the gear case if people get mad and start slamming into gear. A lot of problems on the 2001 and 2002 models on creeping,hard shifting also was wear on the front clutch one way bearing, the fiber and brass washer being the main culprits. Belts would drift over,touch the inner clutch sheath and the machines would be hard to shift into gear or creep making it almost impossible to get them in gear unless you killed the engine. Addressing the front washers(changing the brass washer to steel)replacing the fiber washer usually solved this along with shimming out the rear clutch as needed.Plenty of posts on this along with this one. 2002 500 Sportsman belt alignment - ATVConnection.com ATV Enthusiast Community I wouldn't blame the reverse indicator on the shift box or linkage,but possibly on the shift switches that were moved to the gear case. The plastic levers/arms on the switches can cause problems when worn down along with the wiring or connectors in not showing the correct gear position.Later models went to a lot tougher type of switch. Plus when they changed part numbers on these two switches it kinda tells you that they were updated for a reason. Items #12 and 13 on the parts break down. Dirt Cheap Yamaha, Honda & Polaris OEM Parts & Accessories – Cycle Parts Warehouse