I have an AC 500 Auto, when I shift from low to high it will sometimes grind the gears and remain in low. If I move the shift lever from high to neutral then back to high it will be fine. I recently posted this question and several of you said the idle was too high. I adjusted the idle lower and this was no help. I took the bike to the dealer for adjustment, and this to was no help. Like the old saying goes, "if you want something done right then do it yourself."

I'm planning on adjusting this myself, has anyone done this and do you have any tips or advice?

 

mine does the same.......only I'm not gonna worry about it.......I guess I figured it wasn't that big of deal and not worth my time to tear it all apart when it only takes a fraction of a second to shift to N then back to H

 

Hey vrz500tbx, it could not have been easier! First, under the wheel well you will see the plastic shift cover. Using a phillips screwdriver and the torx tool porvided in the Cat tool kit, remove the hardware and the cover. Loosen the lock nut then focus your attention to where the linkage rod attaches to the engine. Using a small screwdriver remove the c clip and the flat washer. The linkage will come off of the bracket. I gave the linkage rod one complete turn counter clockwise and reattached it to the bracket. A quick test drive and I determined the problem still existed. So after repeating this two more times the bike now shifts perfectly in all gears! Tighten the lock nut and replace the shift cover, another test drive and A OK!

I encourage you to do this, it is very easy, just don't loose the hardware. Oh by the way, when I removed the shift cover I noticed the dealer did not tighten the linkage lock nut. As I said, "if you want something done right, do it yourself."

'04 AC 500 Auto Lime Green
Warn winch w/Amsteel synthetic rope
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