Hello, been working on my 01 Foreman 450 es for over a week now! Searched forum and don’t know where to start! Will not shift using push buttons to shift up or down! I can manually shift it thru all gears with the manual shift lever! On the display it will show, neutral, reverse, 1st and 5th gear! 2nd,3rd, and 4th gear do not show on display! When I use the push buttons, I don’t even hear a click ! Checked all fuses, tried another angle sensor, still no luck! Also adjusted clutch, I believe it’s good as I can manually shift thru all the gears! Any help would sure be appreciated! Thank you

 

If several gears don't show on the display there is a problem with the multiple contact rotary gear indicator switch or the wires from it. I would not have expected it to cause trouble until you get to those gears though. So if it won't change from neutral into 1st or reverse when you start up, you have another problem. Most common on older ES bikes is either worn out brushes, or magnets dropped off, in the shift motor. Take it apart and check. While you are there, check the shift motor gears are well greased and that oil isn't leaking into it from the clutch housing. Warning, the shift motor is a pig to get back together.

 

Have taken shift motor off and bench tested with 12 volts and the motor runs in both directions when I switch the leads! I even tried switching the shift motor out with a spare O.E.M one I have ! Thank you for responding!

 

Do test on the gear shift switch in the rear of engine manual shift gears with contact buzzer type meter leads on each wire may need to get a service manual to I.D wires

 

I would begin to suspect the shift button wires if you are sure the motor is OK. If the feed wire (black/red) to the buttons has broken, it won't get any signal from the buttons to change gear, and those wires move as you turn the steering, so do not last for ever. Check at the back of the switch unit, if it is live with ignition on.

 

I got 5 volts at the push buttons! Still working on the troubleshooting! Thanks for the idea to check!

 

Another question for you! I have my 01 Honda Foreman 450es shifting now with the push buttons , but 2nd, 3rd and 4th do not show on the display! Any idea as to what I might be able to troubleshoot shoot going forward? Much appreciated! Thanks

 

Papa hog scoot answered that above. Wire colours are grey = reverse, light green/red = Neutral, white/green = 1st, white/red = 2nd, blue = 3rd, yellow = 4th, light blue/white = 5th. These are the colours from the switch to the grey multipin connector to the left and above the pull start handle on the frame. Each pin earths when in the gear corresponding to that colour. If the white/red doesn't earth when in second, or blue in third, either those wires are broken or the switch is bad, not worth the strip down to cure the switch, a pig of a job involving swinging arm removal and the back engine case. Get a manual before attempting it, if you must.

PS. Tell us what fixed the shifting problem so someone else can fix it too.

 

It started shifting using the push buttons after I took apart every plug / connector I could locate! Used electrical contact cleaner and then dielectric grease! Still doesn’t show 2nd, 3rd , and 4th gears on display but shifts thru all the gears nicely! I am having a hard time removing the big plug that plugs into the bottom of the ECU! Not sure how it gets removed , I am afraid of breaking something or pulling out a wire! Still trying to troubleshoot the 3 different gears that don’t show on display!

 

Does the atv shift into the gears 2nd 3rd 4th and takes them?