Before I get to my question I should probably let you know why I'm asking it and where I am in my shift problem solving:

I have a 98 Foreman 450 ES and like a lot of ES owners am encountering shift problems. Spent the last week or so learning about it taking it apart and putting it back together. I have the shop manual and have gone through the troubleshooting section step-by-step at least three times convincing myself that I've done it correctly.
Manual shifting works fine. And yes, I could avoid all this nonsense by simply adding a foot shift lever, but I'm an idiot.

I've replaced the angle sensor, the shift motor and the ECU just because. I've cleaned and re-greased the reduction gears adjusted the clutch, etc.

The Combination Meter shows Reverse, Neutral,1st and 5th gears but not 2nd, 3rd or 4th. This seems to indicate the the gear position switch is functioning properly. 2nd, 3rd and 4th shows up on the combination meter based on input from a couple of sources...

Ok, here's my question:
When shifting gears - either manually or with the pushbuttons, does the gearshift spindle (see attachments), rotate incrementally each time you change gears or does it just pulse and remain in the same position? The end of the spindle is like a half-round and the angle sensor fits over the shaft end so that when you shift, the spindle rotates and the angle sensor senses the position and translates the information into a gear position which then shows up on the combination meter.

In my case, the spindle just pulses or jumps and remains basically in the same position - ie, the half-round end does not rotate incrementally to five different positions.
I hope this makes sense. I have one final troubleshooting step to take today and that is to measure the resistance in the angle sensor as I shift - or attempt to shift - through the gears.

Thanks for your interest and any input.

 

The gearshift spindle returns to the same position after each shift.

Are you able to shift at least once when you first turn it on?

Do you have to use a lot of pressure to manually shift, or is it fairly easy?

 

Wow! Good Morning Steve!
Thank you for that bit of info. I didn't know if anyone out there would know that.
99% of the time it will not shift when I turn it on. When I put it back together this last time and pressed the shift button, it upshifted - I about fell of my stool. It also downshifted. But after that nothing. It does seem difficult to shift manually.
I've measured the resistance through the angle sensor. If I am doing the calculations correctly, downshift resistance is within range, but upshift is off by about 1.2. Not sure if that's significant though.

Thank you for your help.
R

 

I assume you know the resistance varies from about 1000 to 5000 ohm.
The angle sensor is usually not the problem.

I also assume you know the picture above is missing a gear.

I think I can help you fix your Foreman. The first step is to get an ECU Bypass Relay System at:
http://subzerosound.com/HondaECUBypass.html
The computer only works well if everything else is working well.

 

Thanks Steve.
I'm going strictly from the manual for the resistant readings -- I'm not that smart.
The gear that's missing is on the motor side.
I'm off running errands, but will check into the link you provided as soon as I get back.

Talk more later.

r
I do appreciate the help. the local ATV shop - Grace Performance - if helpful, but they really want to service it and that gets expensive.