My wifes 2004 outy has developed a shifting problem. The lever does not engage in the right spots. It is off about a quarter of an inch.
So
- Park is in the middle of P and R
- Reverse is in the middle of R and N
- Neutral is in the middle of N and H
- High is in the middle of H and L
but low can't be engaged.

Has anyone else has had this problem?

I am thinking it's either a loose motor mount, or just a shift lever adjustment. Her machine just hit the 500mi mark, so this is possible.

I ordered a shop manual but it is not in as yet.

What are the torque specs of the motor mounts?
I will start with this route, if they are within spec, I will then inspect the shift lever assembly very closely for slop in the joints. If no slop present, I will adjust the shift lever.

What are the measurements for the adjustments for the shift lever and assembly?

Thanks in advance for your suggestions. I hope to get the manual soon.
I hate pestering for easy accessible information..

 

My wifes 2004 outy has developed a shifting problem. The lever does not engage in the right spots. It is off about a quarter of an inch.
So
- Park is in the middle of P and R
- Reverse is in the middle of R and N
- Neutral is in the middle of N and H
- High is in the middle of H and L
but low can't be engaged.
>>>>>>>>>>>&gt ;

I have the exact same problem. First started when my G/F got a little scared going up a hill so she stopped and tried to push it into park but it was a little sticky so she tried to force it and bent the shifter a little bit. After I monkeyed around with it a bit I got it to work but sometimes it still will slip (or wont engage) properly when in the right slot, other times it works just fine. The Outlanders are notorious for this glitch, it's never been a real problem for me but for those not used to riding one it is a bit of a hassle at first. I always make sure to press the rear brake when shifting. Generally the shifter gets a little bent from trying to get it "unstuck". I have found though that even if it's isn't exactly in the right slot it will still work just fine.

 

My brother in law took it for a quick spin yesterday. It was quite evident what was the problem after I took the plastic off. The shifter was bent.
I straightened it out. You guys weren't kidding, that shifter rod is small!

On other notes, the Outlander is a great machine to work on. I never seen a machine plastic's so easy to take off to make all the mechanical components easily accessible. I bought some exhaust rap. My wife complained that her leg got hot. No wonder!.... Their is no heat sheild to speak of.