I know this issue has been beat to death, however, I have a shift problem. I have an '02 4x4 Rancher ES that has had problems shifting for the last year. It would always shift up OK, but it had trouble shifting down, I would have to turn the key off and rock it and it would shift back to neutral. I finally got around to looking at it and after reading several posts on here, I decided to start by checking the Shift Angle Sensor. The battery is fine, 12.7 volts. The resistance to the angle sensor checked fine (4.7k ohm) through the harness, but the resistance did not change when I manually up-shifted or down-shifted, I understood that the resistance should change. So I bought a new angle sensor and it still won't shift, and the resistance doesn't change when I spin the inner circle on the new one either, or manually shift up or down, shouldn't I see the resistance change?

It shifts fine with the manual shifter and the display shows the correct gear as I shift through the gears. There are no flashing codes. Before I started this project, it would shift up just fine with the button and shift back down occasionally. Now when I hit the up or down button I don't hear any click, it doesn't attempt to shift, which makes me think something may have come unplugged. I checked the fuses behind the battery and they are all fine. I made sure the 22P connector is plugged back into the ECU securely, and made sure the new angle sensor is plugged in securely.

I have 12.7 volts on the black/green connector on the grey 22P plug, I also have 12.7 volts between the red/yellow in the 5P plug with the switch on. I have continuity between the green terminal and ground in the 5P connector. I'm not sure what to do next. Any suggestions would be welcomed, I'm not ready to load it up and take it to a dealer just yet. Thanks

 

Your shift motor could be going bad i have replaced them in a few different honda. And another things which suck but true sensor can be bad right from the factory ive seen it alot work in a dealership.

 

I was curious if I could have received a faulty angle sensor. Do you know if the resistance should change while I spin the inner part of the angle sensor? It didn't change when I turned it on my old one or new one. I'm also stumped as to why nothing happens when I hit the up or down shift buttons, no clicking or anything, at least that worked before I started this. Thanks

 

its hard to say sometimes i get the right reading and there still a junk sensor. Another thing to check would be cluch adjustment the 14mm nut with the flat blade screw is your clutch adjustment loosen the nut and turn the screw counterclockwise till you feel tension then a quater turn back clockwise that will set the clutch adjusment another easy thing to check. That would be located on the front case cover left side.

 

I'll check the clutch adjustment. Thanks

 

I adjusted the clutch and that didn't help. When I hit the up or down shift, it still won't do anything, no clicking or anything. Any one know of anything else I can check? Thanks

 

One of the biggest things I have run accross is bad ele. connections...
Disconnect EVERY ele. connection on the bike one by one and blow out any dirt and water.
Then use silicon grease to water proof the connections.
my bike is a 04 rancher at... never replaced the angel sensor or anything but regular maint on the brakes and swingarm bearings. I ride deep water and mud all the time at busco beach, good luck and keep us posted.