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Discussion Starter · #1 ·
Hello,

I have a 2013 Honda Rancher 420FPA (420AT) which has a burnt out shift motor. The machine has approximately 4000 miles on it and has up to now been relatively trouble free (other than a shift angle sensor back at around 2500 miles).

One week back it quit shifting while out riding and I ultimately ended up stuck in gears 1-2. I eventually limped it back and began troubleshooting. In my troubleshooting I found that 30A fuse Main 1 was blown and chased that down to a bad shift motor (I know its bad as if I give it 12 volts directly to the battery it draws 60+ amps where as a good motor with no load is less than 1amp).

I procured a new Honda shift motor and installed it. I also cleaned off the old dry grease on the shift motor gears and put some new grease on the gears (though in reading these forums I messed up a bit here as I used some typical #2 grease out of a grease gun and smeared it on the gear teeth when I should have just used a very thin coating of something lighter). With the new shift motor installed it ran good for one ride. Well, it seemed to fight me getting into the gears right off the bat, but once everything warmed up it seemed to work great cycling through the gears. The second ride out a few days later and it was shifting poorly and eventually not at all. Ultimately the new shift motor ended up burnt out along with fuse Main 1 being blown (this didn't blow right away as I checked it throughout the ride when it would not shift). Ambient temps have been in the 40-50*F.

Using the emergency shift lever everything feels smooth. With the shift motor still on the shifting is kind of mushy due to the drag of the motor, but with it off the transmission seems to shift through the gears. With the AT, how many upshift and downshift gear positions should I have to check? Is it still just R+N+5gears?

I came across a post here on the forum that mentions having to replace the PCM with the shift motor when the 30A Main 1 fuse is found blown. Am I reading this correctly? If that is what it takes, then so be it, but I hate to be shotgunning expensive parts at the problem. I plan to take the PCM out and open it up for the good old sniff test to see if any components look damaged, just haven't done it yet.
(well it looks like I can't provide a link on my first post, so I will try and put this link up in a follow up post)

Oh, lastly, I don't recall getting a code with the first failed shift motor, but with this second one I am getting code 24 Shift Control Motor Drive Circuit.

This post wandered a bit, but I guess I'm looking for advice/experience as to where to go from here. Is it likely that the first shift motor just happened to be a normal failure and then my second motor failed due to a combination of my thick greasing and not replacing the PCM? I have another 2011 that I could rob parts off of for troubleshooting, but it is owned by a family member and I am apprehensive to break it and have two of them down.

Thank you for your time.
 

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Discussion Starter · #2 ·
The link I was trying to post...
 

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Discussion Starter · #3 ·
So I spent a little more time with the machine today. I had shift motor removed for these checks. When shifting the transmission with the manual shift tool I noticed that the shift lever was not returning fully to the center position to allow performing a second shift. Instead I had to jiggle the shift shaft a bit before I was able to shift again.
I performed the same check on another 420AT that is not failed and even with the shift motor still on it, it returned back to center. So, this is kind of suggesting that there is something mechanical broken inside of my transmission. In my searching, the only thing I have come across that seems like a useful suggestion is this thread and associated YouTube video. https://www.hondaatvforums.net/threads/trx420fa-shift-issue-solved.128458/#post-1281490 But, this post looks like it is for the newer machines and I'm not sure how much similarity there is between my 2013 and the 2016 in the video.

At this point I can only assume that what is broken has something to do with the shift return spring. Are there any other possible ideas besides the shift return spring? It appears from the video that to get to the shift return spring the engine/transmission needs removed from the machine and then the front housing pulled off, is that correct or is there an easier way? Anyone got some links to a forum post or video on the most efficient way to get all the way to removing the engine?
 

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Discussion Starter · #4 ·
Well I believe I have found the cause. It is the same broken shift return spring stud that Southernspeed had in the thread I linked in the third post. Partzilla lists it as "PIN, GEARSHIFT RETURN SPRING" part number 24652-HA0-000. Now to get the parts on order and throw it all back together.
 

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Discussion Starter · #5 ·
One last follow up post. Finally got the new pin and shift motor in. From the quick spin I took around the block it looks like all is well. Had to remove the motor/transmission from the frame to get access to the broken pin and was able to drill it out with a left hand drill bit. I drilled about 1/4" into the broken pin before the bit grabbed enough to fully thread it out of the engine. Took around 3-4 hrs to take the ATV all apart and get to the pin and another 3-4 hrs to put it all back together. I'm sure with a little more experience this would have gone faster.
 

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One last follow up post. Finally got the new pin and shift motor in. From the quick spin I took around the block it looks like all is well. Had to remove the motor/transmission from the frame to get access to the broken pin and was able to drill it out with a left hand drill bit. I drilled about 1/4" into the broken pin before the bit grabbed enough to fully thread it out of the engine. Took around 3-4 hrs to take the ATV all apart and get to the pin and another 3-4 hrs to put it all back together. I'm sure with a little more experience this would have gone faster.
Hello
I have a 2013 rancher 420 fa that apparently seems as going into gear with a minor jolt and when accelerating does not do anything, no blown fuses and will attempt to check shifter motor, or where should I start my search for the problem.
 
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