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Discussion Starter #1
Purchased this in April and the electric shifting has been flawless, until today. Its about 36 DegF and its been colder. Could not get it shifted into reverse and it upshifts fine, just not downshifting when cold. Is this normal? I was planning on riding in the snow this winter. What can I do? , Not selling and buying a manual shift for sure.
 

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Two things have to happen to shift into reverse, you have to engage the reverse lock out and then shift. So where does the problem seem to be? In the cable or actually shifting?

Does it seem like your reverse lock out cable is moving freely? Could be it has moisture in it and it is now sticking since it is colder.

You can take the shift motor off, and then the cover for the gear assembly behind it, clean out all the old grease to see if that helps. Check out a parts diagram so you have an ideal of what I'm talking about.
 

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The ES models need a fully charged battery to shift well—that would be my best bet is your battery is old.
Secondly I would adjust the clutch.

The grease in the shift components can give problems. Some threads here on how to clean these parts and replace the grease. Check threads by Retro or maybe current members can chime in
 

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Discussion Starter #4
I got to wondering last night, its only downshifting issues. Could it be the Down side of the shifter controller buttons on the handlebars have bad contacts, like dirt or something? I will sure check the shifter motor and clean out the grease and thanks for the replies!!'
 

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I got to wondering last night, its only downshifting issues. Could it be the Down side of the shifter controller buttons on the handlebars have bad contacts, like dirt or something? I will sure check the shifter motor and clean out the grease and thanks for the replies!!'

Sure it could be a problem with just the downshift button. Try shifting it while its not running; you may have to rock it back and forth to get it to fully shift. But if it seems like it shifts ok when not running vs problems shifting while it is running then you have a clutch issue. Adjusting the clutch should fix that.
 

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Discussion Starter #6
Sure it could be a problem with just the downshift button. Try shifting it while its not running; you may have to rock it back and forth to get it to fully shift. But if it seems like it shifts ok when not running vs problems shifting while it is running then you have a clutch issue. Adjusting the clutch should fix that.
OK thanks, just got home from doctors office and went out, it does shift better in my 45 Deg garage but If I can find those connectors they show in the manual page 22-21 10P and I am thinking ECU 22P is on the ECU module I will check the switch contacts. Next the grease. Thanks again to all who provided replies!!
 

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Remember to re-grease the shift motor gears with lithium grease or silicone based grease, don't leave them dry..!!
For the shift switch... Contact cleaner spray will work well. I'd use a moisture inhibiting spray after cleaning, such as WD40 or GT85.
 

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Discussion Starter #8
Ok Finally got to work on it. Took off the lower black plastic on the drivers side and got the 5 10 mm (socket size) bolts out and dropped motor and wiring out. Gears had some old dark brown stuff on and heeding the advice not to move those gears used, WD40 cleaning brush and CRC brake cleaner and got all off. Blew out with some gentle air not full 90 psi. O ring gasket looks good so tomorrow after it all dries I am going to spray all with Lithium grease and put some out of a tube on to the gears. Small amount and then get it all back together. Silicone grease on the connections where I can. I am assuming blue locktite on the bolts. Suggestions?
 

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you dont need loc-tite on the bolts, no reason for it.
 

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Discussion Starter #10
Ok thank you, the gears look as if they came right off the assy line. I did not what to screw anything up.
 

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Discussion Starter #11
Ok got the new white lithium grease grease in and back together along with silicone on the plug connection. Seems to shift fine now, wonder how the cold weather shifting will go? Ordered a kit of 8 mm dart connectors to replace the plastics and then a few more missing. Thanks for the help guys!!
 

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Discussion Starter #12 (Edited)
I'm Back, so the problem is still there mostly on the down shift. Took the handle bar switch apart 3 screws one behind the lever bracket. Yellow cable in back is drop light. The screws were Not real tight, and when apart I found a little spider web nest inside. I am assuming the white plastic blocks are activating switches,, the two round black things with two wires out of each? Anyway tomorrow blow out, clean and test before moving on and I have the right side, most of the plastic off anyway and lots and lots of dirt!! PS the front switch picture has been inverted to match the rear view of the wiring.

IMG_4514.JPG IMG_4508.JPG
 

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Discussion Starter #13 (Edited)
Well I pulled the left handlebar apart and ohm meter checked the switch and it appears to be fine when I tested, Now looking for a wiring diagram or at least the locations of those connectors or plugs in the circuit to check. At the amount of dirt and grime I have found I would suspect a connector with that crud in it and cleaning and dielectric grease treatment. Thank you in advance. Ok ding, I found my downloaded Service Manual. Never mind.

PS Yes the round objects in the picture were switches and they are well sealed. The way I ohm meter checked was sharp needles that pierced the wire insulation. They will be resealed with silicone gasket sealer as well as the entire housing when I am done.
 

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Purchased this in April and the electric shifting has been flawless, until today. Its about 36 DegF and its been colder. Could not get it shifted into reverse and it upshifts fine, just not downshifting when cold. Is this normal? I was planning on riding in the snow this winter. What can I do? , Not selling and buying a manual shift for sure.
It has been happening to me alot and it isn't cold and all other gears work, it is probably the angle sensor or shift motor, my uncle's 2005 Honda Foreman 250 has no gears. Is yours a fourwheel drive or two wheel drive model?
 

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Discussion Starter #15
It has been happening to me alot and it isn't cold and all other gears work, it is probably the angle sensor or shift motor, my uncle's 2005 Honda Foreman 250 has no gears. Is yours a fourwheel drive or two wheel drive model?
Mine is 4WD, and jury is still out on if its fixed on not. Got involved in another project but the gears were cleaned of the old grease and the white lithium grease installed. But in the mean time I discovered the battery even if it said 12.6 volts was not holding a charge after a small load was applied. So I ordered a new battery off Amazon and from a US vender and maker of batteries. It came in reading only 12.3 volts and it was a AGM $100 plus model, charged it and next day its down to 12.5 volts just sitting on the workbench! Back it went and went to O'Reillys purchased one locally (AGM) and it is fine, read 12.8 volts the next day after a charge. I need to road test but sitting in the shop it seems to shift fine.
 

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Mine is 4WD, and jury is still out on if its fixed on not. Got involved in another project but the gears were cleaned of the old grease and the white lithium grease installed. But in the mean time I discovered the battery even if it said 12.6 volts was not holding a charge after a small load was applied. So I ordered a new battery off Amazon and from a US vender and maker of batteries. It came in reading only 12.3 volts and it was a AGM $100 plus model, charged it and next day its down to 12.5 volts just sitting on the workbench! Back it went and went to O'Reillys purchased one locally (AGM) and it is fine, read 12.8 volts the next day after a charge. I need to road test but sitting in the shop it seems to shift fine.
anything from amazon is china junk !.
 

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Sorry the battery was made in USA. I also had it in my hands and saw the label. I believe it was old stock as the one I got locally, same made in USA but build date 9/19.
maybe parts of It was made in usa ?, but if it came from amazon ?, chances are it was made in china ?, thats a gamble I would not want to take. 9/19 is not that old, spec with a agm battery.
 

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Discussion Starter #19
maybe parts of It was made in usa ?, but if it came from amazon ?, chances are it was made in china ?, thats a gamble I would not want to take. 9/19 is not that old, spec with a agm battery.
That was the new battery from O'Reillys date 9/19, the other battery from Amazon had a Made in USA and flag on it and it was made out east someplace.

149522
 

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