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Discussion Starter #1
Hi Everyone I have a 2002 Honda Rancher 350 ES 2x4 that is stuck in reverse. Just a little background on this issue. While riding one day I noticed that the speedometer was not working, after that my rancher started sticking in fourth or fifth gear when running at high speed. It would not down shift unless I turned the engine off and back on then I had to rock it back down into neutral. So the first thing I did was replace the speed sensor. At first this seemed to have fixed the shifting and speed sensing issues. This worked for several weeks until one when I backed my Rancher up to a trailer and it stuck in reverse. I have tried the manual shift, and replaced the angle sensor neither has fixed the problem. The shifter motor still clicks as if it is trying to shift the gears but it is still stuck in reverse. Just a little history on the bike itself I bought this bike back in 2002, it hasn't been rode to hard it's main use has been for light riding and hauling wood. If anyone has any idea as to what I need to do next please feel free to join in. Any help would be appreciated. Thanks
 

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How old is your battery? Electric shift models need to have a good battery. If your battery is older than 5 years, replace it. Also keep the battery fully charged by connecting a battery tender to it when not in use.
 

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If it wont shift out of reverse with the emergency manual shift then its likely you've got an internal problem.

I remember there was a recall for the gear shift plates on these. ive had a couple 350's that broke and did what your describing.

Not a bad repair, either way your gonna need to tear into it to rectify the issue.
 

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If you cannot shift it out of reverse using the manual shifter tool, then likely there is an internal issue. Check the gear position switch to make sure that it hasn't broken open and fell apart first. But I suspect you'll find the problem might be in the drum linkage behind the front cover. You'll need a copy of the service manual to guide you. Look in the manuals thread for a link to a manual if you haven't gotten one yet.

Let us know how it goes if you can.

EDIT: Manny types faster. LOL :)
 

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sounds like a engine split case to me ?. another electric shift model that makes me cringe !..lol.
 

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Nah... his bike is an '02, it has the updated shift drum fix from the factory. :)
the early ranchers is where all the shift drum problems started, then in the later years they were having problems with 4th gear if I remember right ?. hopefully its at the front like ya said !.
 

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Discussion Starter #8
Hi everyone thanks for the replies I tried the shift tool today and it let me shift it into neutral with no problem. So I started it up and let warm up then I took it for a short ride around the house. Now first it let me shift in all gears smoothly, then it started sticking in fourth but it would let me down shift to third and etc.So the next thing I did was cut it off and on again this time it didn't want to shift out of first, but it would shift down into neutral and even reverse. I also shifted in reverse a few times, it shifted smoothly from reverse to neutral but it again stuck in reverse. So I used the shifter tool again with no problem to get it back in neutral. Just to note my battery is only a couple of months old and I checked the voltage and everything is good. So if anyone has any ideas I'm all ears Thanks
 

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Hi everyone thanks for the replies I tried the shift tool today and it let me shift it into neutral with no problem. So I started it up and let warm up then I took it for a short ride around the house. Now first it let me shift in all gears smoothly, then it started sticking in fourth but it would let me down shift to third and etc.So the next thing I did was cut it off and on again this time it didn't want to shift out of first, but it would shift down into neutral and even reverse. I also shifted in reverse a few times, it shifted smoothly from reverse to neutral but it again stuck in reverse. So I used the shifter tool again with no problem to get it back in neutral. Just to note my battery is only a couple of months old and I checked the voltage and everything is good. So if anyone has any ideas I'm all ears Thanks
some fresh grease in the elec transfer gear area may help you !. this is at the front, where the electric shift motor is. DO NOT PULL THE ELE SHIFT MOTOR APART !..LOL. just remove all the cover bolts holding the ele transfer gears, clean out all the old grease, put some fresh grease back in, should help it shift better :).
 

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i used 100% synthetic marine grease on the 2000es, shifter motor. might be something better..
 

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Discussion Starter #12
Thanks guys for the reply. Greasing the gears seems to be the easiest way to go for now lol. What kind of grease would be best. Also is the there a diagram showing the gear positions just in case something comes out of place. Do you guys thinks this may the reason for the shifting problem?
 

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Thanks guys for the reply. Greasing the gears seems to be the easiest way to go for now lol. What kind of grease would be best. Also is the there a diagram showing the gear positions just in case something comes out of place. Do you guys thinks this may the reason for the shifting problem?
I use plain ole wally world high temp grease. most times, the factory grease is not worth a dang, clean it all out, fill it fresh with new, bolt it back together. no spec way the gear position goes, other than placing them in right, working your way out, grease the gear teeth as you install them, service manual shows ya how to install them. the large y-shaped gear, just center it on the small round gear, this leaves enough room for it to travel both ways when it works.
 

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Discussion Starter #15 (Edited)
Thanks again guys for the advice. I will grease the gears and let you know how it turns out. Is there a way to view the service manual online? If there is anything else I should check out please let me know. I also will check the voltage on the battery.
 

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Ok guys I have cleaned and greased the gears with while lithium grease and put everything back together. First thing that happened was it stuck in 2nd so it let me down shift into neutral and in to reverse where again it stuck. So I used the shift tool to put in neutral. After that I while sitting still I used the shift tool to go through all the gears 1-5 after which I turned the switch off on on again. Then I was able to electronically shift through all the gears including reverse and back to neutral. So I took it for another spin. Everything was shifting fine, even in and out of reverse. and then it happened again it stuck in reverse and I used the shift tool to return to neutral it repeated the same cycle of shifting great then sticking in reverse, So now I'm trying to figure out what is the next step. The rancher runs good and strong the only problem is the electric shifting. If anyone have any suggestions please let me know. Thanks
 

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Yeah, four things you can do to fix it...

1) Replace the battery with a new one of the proper size. ES bikes require a good healthy battery in them at all times.

2) Clean and freshly lube the shift motor. I left ya a link to a shift motor howto earlier in this thread.

3) Change the motor oil and oil filter. Be sure to buy a JASO MA certified motor oil for it.

4) Put on a confident smile and enjoy your handi-works.
 

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Ok guys I have cleaned and greased the gears with while lithium grease and put everything back together. First thing that happened was it stuck in 2nd so it let me down shift into neutral and in to reverse where again it stuck. So I used the shift tool to put in neutral. After that I while sitting still I used the shift tool to go through all the gears 1-5 after which I turned the switch off on on again. Then I was able to electronically shift through all the gears including reverse and back to neutral. So I took it for another spin. Everything was shifting fine, even in and out of reverse. and then it happened again it stuck in reverse and I used the shift tool to return to neutral it repeated the same cycle of shifting great then sticking in reverse, So now I'm trying to figure out what is the next step. The rancher runs good and strong the only problem is the electric shifting. If anyone have any suggestions please let me know. Thanks
it's posb your ele shift motor is bad ?, or..you have internal damage ?, or, angle sensor is bad ?. pull the shift motor out of the front cover ( in one piece !.lol )..hook 12 dc volts to it, see if it spins ?, then reverse the leads, see if it spins ?. if it does good both ways ?, then move onto the next..angle sensor !. if that is not the problem ?, then you have internal probs. but !!!, seeing how it shifts at times, then won't , I would guess its at the shift motor ?, angle sensor ?, or worse case, at the front where the front of the shift drum is ?. THIS IS WHY I HATE ES MODELS...THEY ARE NOT WORTH MY TIME..LOL.
 

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Discussion Starter #19
Thanks guys for the reply, those are some good things to consider. I just put a new angle sensor on this bike just about a month ago when this whole shifting problem started, the battery is only about three months old. Could it be I have got a bad one. If you guys have anything else to add I'm all hears.
 

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I got nothing else for ya right now if the battery is the correct one in it and is in good condition? Change the oil and do a good job on that shift motor (and don't forget to repack the reduction gears bearings) and if you still have an issue after it is cleaned up and lubed then hollar back.
 
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