[Hunterspaw]

I have a 2002 Honda Rancher 350es and I can’t get it into any gear. It was at first stuck in reverse. I changed the shift change control unit which is found under the rear right fender. Once I done that and shifted up once or twice it took it out of reverse but never hit neutral or even showed a gear on the display screen. The “gear position” box on the screen is just blank and won’t show. But the neutral light never came on. If somebody knows anything or can help that would be great! Thanks in advance!


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[retro]

The shift motor might have gotten water inside it. Or the shift motor may be going bad... worn out brushes, bearings etc., causing excessive current draw. Or, the reduction gearset may have a gear with a broken or chipped tooth. Any one of those might smoke the ECM again if not corrected.

While you are checking the shift motor and gears out, take each gear out and wash them in solvent. Inspect them and inspect the supporting bearings in each half of the housing. Make sure none of those bearings are cocked in their bores. If you find that a gear has been rubbing on the housing straighten up those bearings. Then push some quality grease past the shields on each bearing using your finger, packing each with grease. Then coat each gear lightly with grease (coat the gear teeth) and reinstall them, making sure the lower gear is installed on center. You can download a copy of the service manual HERE to use for reference.

Then move on to testing the shift motor. You can put 12 volts on it on the bench to see if it runs. Reverse the polarity of your 12 volt leads to test it in the opposite direction. It should torque over strongly and rev up immediately in both directions. Let us know how the shift motor tests out before you go out and buy one. We might be able to solve that problem.

If you buy any parts buy genuine OEM Honda only, or you'll be buying them again immediately. DO NOT put ANY china parts on the bike. Those are all garbage dumped here to rob you, destroy your standard of living and destroy the value of your Honda! Have fun!

 

[Hunterspaw]

The shift motor might have gotten water inside it. Or the shift motor may be going bad... worn out brushes, bearings etc., causing excessive current draw. Or, the reduction gearset may have a gear with a broken or chipped tooth. Any one of those might smoke the ECM again if not corrected.

While you are checking the shift motor and gears out, take each gear out and wash them in solvent. Inspect them and inspect the supporting bearings in each half of the housing. Make sure none of those bearings are cocked in their bores. If you find that a gear has been rubbing on the housing straighten up those bearings. Then push some quality grease past the shields on each bearing using your finger, packing each with grease. Then coat each gear lightly with grease (coat the gear teeth) and reinstall them, making sure the lower gear is installed on center. You can download a copy of the service manual HERE to use for reference.

Then move on to testing the shift motor. You can put 12 volts on it on the bench to see if it runs. Reverse the polarity of your 12 volt leads to test it in the opposite direction. It should torque over strongly and rev up immediately in both directions. Let us know how the shift motor tests out before you go out and buy one. We might be able to solve that problem.

If you buy any parts buy genuine OEM Honda only, or you'll be buying them again immediately. DO NOT put ANY china parts on the bike. Those are all garbage dumped here to rob you, destroy your standard of living and destroy the value of your Honda! Have fun!

What is this part right here and what does it do? Because it doesn’t fit down flush in the hole in the background and I feel like it should. Also, I’ve put a new ECM and a new shift motor in it and still does the same thing.



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[retro]

That part in your photo is the Vehicle Speed Sensor (VSS). It only fits in the case one way with the cable going towards the motor. You'll need to look in the service manual to get it installed right and get the wire routed properly.

Was there something wrong with the shift motor you replaced? What was wrong with it...? Same questions about the ECU, what made you replace that?

 

[Hunterspaw]

That part in your photo is the Vehicle Speed Sensor (VSS). It only fits in the case one way with the cable going towards the motor. You'll need to look in the service manual to get it installed right and get the wire routed properly.

Was there something wrong with the shift motor you replaced? What was wrong with it...? Same questions about the ECU, what made you replace that?

Is the vss a part that could mess up? I replaced the shift motor and ecm because I first couldn’t get it out of reverse then when I changed the ecm it got it out of reverse but now it won’t go into neutral and I changed the shift motor thinking that may be the problem but it still does the same thing.


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[Goober]

As retro suggested i would follow the diagnostics in the manual, first ensuring that the battery is in top condition (how old is it) and a clutch adjustment.
Can you shift it manually with the special bar (should be in the tool box).
With your hand not your foot—Don’t force that bar—break that shift rod and you will be unhappy.
Might be gear position sensor. Follow the manual first.

 

[Hunterspaw]

As retro suggested i would follow the diagnostics in the manual, first ensuring that the battery is in top condition (how old is it) and a clutch adjustment.

Can you shift it manually with the special bar (should be in the tool box).

With your hand not your foot—Don’t force that bar—break that shift rod and you will be unhappy.

Might be gear position sensor. Follow the manual first.

The battery is only couple months old so it’s very healthy. But yeah I’ll have to look in the manual. It’s ES and you can hear it shifting up and down but never hits neutral.


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[retro]

Use the shift wrench by hand as Goober recommended, while rolling the bike back and forth as you down shift. Let us know if it still will not shift... that could indicate a mechanical problem internally.

 

[Hunterspaw]

Use the shift wrench by hand as Goober recommended, while rolling the bike back and forth as you down shift. Let us know if it still will not shift... that could indicate a mechanical problem internally.

Where is the place I need to put the wrench though? I’m not familiar with where to manually do it.


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[retro]

The answer can be found in the service manual. Shift shaft, left side, at the rear of the motor. 12mm wrench fits it if you don't have the OEM tool anymore.

If you can't shift it manually that indicates an internal problem. Report back here and explain what happens when shifting manually. We can help you once we have enough information.

 

[retro]

Did you get the VSS mounted back where it belongs with no issues?

 

[Hunterspaw]

The answer can be found in the service manual. Shift shaft, left side, at the rear of the motor. 12mm wrench fits it if you don't have the OEM tool anymore.

If you can't shift it manually that indicates an internal problem. Report back here and explain what happens when shifting manually. We can help you once we have enough information.

Okay thank you. I will try to get to it tomorrow and also work on getting the VSS mounted correctly.


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[retro]

Put a thin film of grease on the VSS o-ring after cleaning it up. The cable goes toward the front, toward the motor. Make sure the VSS fits down on the flange squarely and make sure the end of it is clean. If it contacts the reluctor after install it will be ruined. So check your work as you go.

Make sure the oil temp sensor wire (light blue) is routed behind its' bracket like the service manual shows too. That one is easy to screw up on if you aren't paying attention to the manual.

 

[beaglebriar]

I'll bet the end of the shift drum is broke. It was a common problem on those.

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[retro]

Shift drums were fixed after 2001... The '02s and up had a larger end on the drums and fit in the existing case by removing the support bearing.

 

[beaglebriar]

Shift drums were fixed after 2001... The '02s and up had a larger end on the drums and fit in the existing case by removing the support bearing.

Lol...they make it sound so easy. I did a few but it's been quite awhile. I was thinking '02 had that issue as well.

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