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I have a 2000 450 ES and a no shift issue. It got stuck in 1st gear so we was rocking it as I was manually shifting to neutral. When doing so, I heard a pop and the shifter just has free play and I can hear the shift motor work as I work the shift arm. Took the front cover off and found the Sub gearshift arm tip broken. 17 in attached schematic, I really thought it would be 16 gearshift A arm from my searching.

So a couple questions. First, when I took the front cover off there was a flat washer that I have no idea where it came from, it was just laying lose on one of the clutch drums. I haven't been able to find it in the manual or parts diagram. Any idea where it goes when I put the cover back together?

Second, I don't see #16 gearshift A arm from what I have read. It is behind the front cover with the shift drum. Is it in the front or rear case?

Would the broken sub gearshift arm cause my problem or do I need to look deeper?

This has been cross posted on another forum. I haven't received any help and I need to get it fixed.

Thank you for any help you can give.
Jeff
 

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#16 is at the back of the long shifting shaft, that flat washer goes on the very end ( outside ) of the clutch arm before you install the front cover. put the emergency shifter wrench ( if you have it ? ) on the hex shaft at the left foot rest, shift gears, watch the shaft that pokes out the front of the engine, if it moves ?, then the shaft is good, if it does not ?, then it could be broken ? ( I highly doubt this..as I've never seen on to break ). most times on es models, the problems are right there in the front..where all your shifting parts are. even with using the emergency shifter on the hex should change gears..but !!!...if the transfer gears at the front are broken, busted, stripped ?, then it won't shift at all no matter what. do yourself a big favor, ditch that junk, and buy a manual shift model..lol.
 

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Discussion Starter #3
@shadetree, thank you for your response. The sub gearshift arm #17 is broken. The tip is broke off, I have a shift lever on the emergency shift. It will not shift with it either. When attempting to shift with the emergency shift it does move, could hear and feel the electric shift motor move. But no mechanical shifting of the gears.
 

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@shadetree, thank you for your response. The sub gearshift arm #17 is broken. The tip is broke off, I have a shift lever on the emergency shift. It will not shift with it either. When attempting to shift with the emergency shift it does move, could hear and feel the electric shift motor move. But no mechanical shifting of the gears.
you pretty much have to have it all back together before it will shift, make sure to check the shifting splines on the shifting shaft to see if they are stripped ?. from what you are saying here, until you get the # 17 replaced ?, and all back together ?, it won't change gears. bottom line: everything must be good, and working, and back together before it will change gears. if the shifting shaft has a broken tip ?, well..your screwed...sorta..the only way you can fix that..is too pull the motor, split it, and replace the long shaft that runs from the front to the back, which ties into the hex shaft i'm afraid. heres how it works: lets say your using the emergency shifter ?, ok..that hex shaft goes in the side, from just inside there, that shaft ties into the long shaft which pokes out the front, at the front, it all ties together to the shifting drum and the electric shifting parts. all the electric shift does..is turns some transfer gears inside the front cover, which spins the shifting plate and ratchet gears and parts at the front of the shift drum. have I lost you yet ?..lol. sooooooooo..if the long shifting shaft can't turn any of the parts at the shifting drums front ?, it won't change gears..period !. I would start with a new part that is broken, look for any other parts that are bad while the front cover is off ?, and replace any parts that need it. if the long shaft is at least turning with the emergency shifter ?, and not messed up any way at the front on the splines ?, well..at least your not pulling the motor, and splitting the motor to replace it ?, because that will be a ton of work, and extra parts. THERE IS NO SHORT CUTS TO FIX THIS !..you have been warned :).
 

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I had to look # 16 up, that part is at the back of the motor, tied to the hex shaft, this is what turns the long shaft I spoke of earlier :).
 

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I have a 2000 450 ES and a no shift issue. It got stuck in 1st gear so we was rocking it as I was manually shifting to neutral. When doing so, I heard a pop and the shifter just has free play and I can hear the shift motor work as I work the shift arm. Took the front cover off and found the Sub gearshift arm tip broken. 17 in attached schematic, I really thought it would be 16 gearshift A arm from my searching.

So a couple questions. First, when I took the front cover off there was a flat washer that I have no idea where it came from, it was just laying lose on one of the clutch drums. I haven't been able to find it in the manual or parts diagram. Any idea where it goes when I put the cover back together?

Second, I don't see #16 gearshift A arm from what I have read. It is behind the front cover with the shift drum. Is it in the front or rear case?

Would the broken sub gearshift arm cause my problem or do I need to look deeper?

This has been cross posted on another forum. I haven't received any help and I need to get it fixed.

Thank you for any help you can give.
Jeff
# 16 is clearly on this micro pic you posted, at the rear of the long shaft, ties to the hex shaft :).
 

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and your welcome :).
 

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Discussion Starter #8
@shadetree nope, didn't loose me. The long shift shaft is turning in the front case when working the emergency shift. So, hopefully part #17 sub gearshift arm is all that is wrong. Should I pull the clutch and centrifugal clutch to check for broken parts or would the Sub gearshift arm cause a no shift issue?

Thank you again for the assistance.
Jeff
 

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@shadetree nope, didn't loose me. The long shift shaft is turning in the front case when working the emergency shift. So, hopefully part #17 sub gearshift arm is all that is wrong. Should I pull the clutch and centrifugal clutch to check for broken parts or would the Sub gearshift arm cause a no shift issue?

Thank you again for the assistance.
Jeff
I think your clutches are ok, but in order to inspect the shifting parts right there at the lower right ?, you may have to remove the centrifugal clutch to gain better access to there ?. but I don't think there is anything wrong with your clutches, and that broken part should fix your issue, that is..if nothing else is bad right there at the front of the shifting drum where all those parts are ? :). and your welcome.
 

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A honda mechanic on another forum says the most common problem is a loose bolt (28)
on the 7 star wheel (6). He also says a bent pawl (12) that moves the star wheel is
the next most common problem.

I would like to know if you have to remove the clutch to fix your problem, for future
reference. I have a work-around on my Foreman to work the shift motor, bypassing
the ECU, and I might eventually need to replace one of these parts.

Shadetree has provided some very good information on the inner workings of the
shift mechanism! But.... I believe the ES shift system works very well and I don't
think anyone should sell their Honda ES to get a Footshift model. Although they
should be careful to not hit downshift when they really want to upshift,
and don't push on the emergency handle too hard - maybe try to push/pull the
atv really hard to move the wheels a ways instead, which may free up the shifter.
 

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A honda mechanic on another forum says the most common problem is a loose bolt (28)
on the 7 star wheel (6). He also says a bent pawl (12) that moves the star wheel is
the next most common problem.

I would like to know if you have to remove the clutch to fix your problem, for future
reference. I have a work-around on my Foreman to work the shift motor, bypassing
the ECU, and I might eventually need to replace one of these parts.

Shadetree has provided some very good information on the inner workings of the
shift mechanism! But.... I believe the ES shift system works very well and I don't
think anyone should sell their Honda ES to get a Footshift model. Although they
should be careful to not hit downshift when they really want to upshift,
and don't push on the emergency handle too hard - maybe try to push/pull the
atv really hard to move the wheels a ways instead, which may free up the shifter.
it's hard to get to the shifting parts on the front of the shift drum at the front, but !!!..it can be done without removing the clutches !. ( yes..I've done it ).
 

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@shadetree it is fixed, part came in today. Was just the sub gearshift arm. Now I just have to put it all back together.

Thank you again for the assistance.

Jeff
your very welcome, glad I could help ya ! :). p.s. and thank you for updating with the fix !!!.
 
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