I have an 03 P650. Before I go in (I have read NYROC's Tips) I want to tap into some personal experiences.
More so cold but not much better when warm I get this spongy feel like I have to force it but it will not force in. I have to blip the throttle to get her in. It is usually when I want to go from hi or lo to reverse but not limited to that scenario.
One more. When descending technical stuff in low 4X4, as the machine lashes to and fro it clunks a bit. I heard this can be a shifter adjustment deal also.

 

Make sure your motor mounts aren't loose. That messes up shifting (and drive lines) real bad.

Also, the shifter will stick by design if the belt isn't tight enough just because the gear teeth sometimes line up straight and they wont engage unless you rock back and forth.

My shifter used to do that. No more now it is tight.

 

My gear shifter got really hard to shift over the weekend when I was using my quad to haul grass in a small pull-behind trailer. Here's what I did to fix the problem.

First, I checked the motor mounts and discovered all were pretty tight except for the front, lower motor mount which seemed only snug (not super tight like it should be). So I loosened up all the motor mounts, jacked up the motor using a floor jack under the engine block and then re-tightened the motor mounts. This helped a little, but only slightly.

Next, I removed the plastic piece around the airbox and loosened up the 2 bolts that hold down the shifter gate. Then I played with the shifter to see which direction I needed to move the shifter gate so as to fix the problem. I discovered that I needed to move the shifter gate towards the right (away from the airbox) and retighted the shifter gate bolts to hold it at that position. After putting the plastic piece back on, my quad now shifts perfect again.

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

I adjusted mine per the NYROC instructions without an issue. However I helped a friend adjust his (2002) would pop out of low gear, adjusted and that does not happen anymore however his neutral safety switch seems to be out now. Won't start in neutral unless the brakes are applied. He's looking into it.