A few questions...
When you run the initialization process, can you hear the shift control motor cycle ?

Also, when the shift control motor is removed, can you spin the gear inside the engine case ?

Have you removed all the connectors from the frame inside the foreward side of the right rear wheel fenderwell and checked for corossion or bad contact (many of the sensors that send crucial signals to the ECM are connected at this point) ?


----- Gimpster -----

 

I did preload the angle sensor..... i took the bike to the garage and they told me it wasnt electrical...... When running the initializing process i hear the motor run.... and since i took it to the garage i'm assuming the connectors were all good...... i looked at them myself and they looked good....

another question .....according to the clymer manual if you cant count the "--" it can be the shift control motor or the gear position sensor..... i checked the motor and it runs good in both directions...... but where is the gear position sensor?? and how do i check it??

Thanks
saby5757

 

When you dis-assembled and cleaned the shift control motor did you clean the commutator bars with crocus cloth or fine sandpaper like #600 then clean it all with contact cleaner, check the brushes , put a spot of grease on the bushing then re-assemble .. ? ..

The only gear position switch this model uses is for the sub-transmission (L , D , N , R) .. The 1 , 2 , 3 , 4 , 5 are numbers displayed by the ECM which are the 5 different swash plate angles ..

 

WoW! Are we talking about a computer or an ATV!!!!!!![img]i/expressions/face-icon-small-smile.gif[/img] IT's amazing how many computerized components and sensors are on our bikes now.... Thank god for the smart guys here on the forum. Good luck, maybe you should call one of those IT guys in India.

 

When i took the shift control motor apart, i cleaned it with sandpaper..... put it all together, attached the wires to the battery directly and it spun fine..... and then switched the wires and it spun fine the opposite way too.....

Interesting what you said about the gear position switch.... in response to the 1,2,3,4,5 being shown by the ecm and the swash plate angle...

When I start the quad in ECM and then before it starts blinking "--" i can go through the gears... when upshifting (it goes in this order) 1,3,4 when downshifting (this order) 4,3,2,1

It skips 2nd gear on the way up but hits it on the way down...... but never goes to 5th gear??? Plus once i shut f off and restart it...it starts in 1st no matter what gear i shut if off in?????

any ideas?

 

A few things,
Are you starting the unit in neutral ?
Is it flashing any codes ?
Are the up and downshift buttons working smooth or are they sticky ?

----- gimpster -----

 

I noticed in the manual when it says "problem code not retrieveable" it says to look at the gear position switch and harness, and the shift switches and harness...

Are you guys thinking it could be one of those switches or wiring?

I see there's a chart showing which pin should be grounded in various positions, along with checking for continuity and/or grounded wire between the two connectors... There should be continuity between the white wire and ground in low, Lb/whi and ground in drive, Lg/R and ground in N, and Gr and ground in R.

For the EPS switches, none should be grounded and no continuity between pins when nothing is pressed. There should be continuity between Whi/Blu and Red/blk when you hold UP, and between Whi/Yel and Red/Blk when you hold Down...

 

I'm still thinking about 2nd not showing while shifting up..

 

The second gear thing has me wondering also. I was thinking a bad shift switch on the left bar. Maybe sticking to skip second.

----- Gregg -----

 

I start the enigne to run the codes in neutral.....however since it sounded like it was in high gear when i hit the throttle, i started it holding the brakes in ESP and then shifted.... I took the shifter off the handle bars and it seemed of....they dont stick...??? As JeffinTD said about the problem code not retrievable........ thats what i was looking at... as i said before i had the wiring checked out at the garage and they said ti was ok....... so the book says gear position switch or shift switches....... i dont know where the position sensor is so i didnt know how to check it.......

the second gear made me wonder too..... but it only skips it on the way up.... not on the way down???

thats why i have waited before i bought any new parts because i wasnt sure.....

thanks for any and all help!!!