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Discussion Starter #1
Hi folks - looking for some advice here. I've got a 2013 Foreman TRX500 ES that won't shift up. I was out plowing the snow yesterday, and I shifted into reverse, backed up, then when I tried to go forward again, the machine wouldn't shift out of reverse. I was just at the bottom of my driveway, so I just backed it into the garage, then left the machine sitting for a few hours, as I had to run to a Christmas party.

Later in the day, I started the machine back up, and it shifted out of reverse just fine, so I drove it out around the neighborhood, and it was shifting normally at that point. I was working through the gears, and everything seemed fine. However, right when I was sure that the earlier issue was a fluke, I got stuck in reverse again as I was testing it out. This time I was down the street, and drove the length of the neighborhood backwards.

Did some research here, and I found kentco's advice on fixing shift problems. I pulled the starter motor, cleaned everything out, then re-greased with white lithium. Once it was all assembled, I was able to shift through all five gears, and back down, but got stuck in neutral. If I use the manual shift tool from under the seat, I can manually work through all of the gears just fine, but I can only use the ES for shifting down gears - it just won't go to higher gears.

Checking the service manual, so far I'm seeing continuity everywhere the troubleshooting says that I should, but I did notice something odd once I worked around to the shift angle sensor. The manual is saying that when I manually shift up, I should see the resistance increase, and decrease when shifting down. However, I'm seeing the following readings when checking pins A & B. I've also checked the resistance across all three pins, and they seem to be within spec of between 4-6 kΩ on pins A & C, and 2-3 kΩ on pins A & B.
  • When not shifting: 3.1 kΩ
  • When shifting down (pushing the lever to the right as if I were sitting on the machine): 4.1 kΩ
  • When shifting up (pushing the lever to the left): 1.9 kΩ
Seems backwards from the manual - as I'm sitting to the left of the machine, and pulling the lever to me, I'm seeing the resistance decrease. Would a faulty sensor start to read backwards like that? I guess I'd expect a bad sensor to just not work at all - not start reading backwards. I guess I'd also expect something screwier to be going on if a sensor was reading backward like that.

For reference, here's the page of the manual I'm looking at:

149465


I also made a short video of the noise the machine makes when I try shifting it. The video shows multiple attempts at shifting up, with one press of the downshift button. Does this provide any clues to anyone? Luckily, the big snow storms have passed for now, so I've got a week or so until the next one in the forecast. Hopefully I can get this thing fixed before then. Thanks in advance for any help you folks might have for me.
 

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Discussion Starter #2
With that being my first post, the board wouldn't let me post a link to the video I made. Maybe it'll let me post a link with my second post?
 

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Discussion Starter #4
Just got in from measuring it, and here's what I got:
  • Motor off: 12.3v
  • Motor on: 13.8v
Left the lights off when measuring, and I did see a 0.1v drop when attempting to shift gears.
 

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It should not be your battery. I have seen similar problems that were a bad battery, it would start the bike but would drop below 11 volt and had trouble shifting.
 

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Discussion Starter #7
The more I thought about the shift motor, and how it worked great in one direction, but not the other, I decided to take a shot at replacing that. I ordered a new motor, which arrived yesterday. Took me about 10 minutes to swap the motors out, but once I did, the machine is shifting just fine again with no issues. Drove it around the neighborhood for a while, working through all of the gears, and having zero issues. Still not sure about the readings I was getting from the angle sensor, but given that things are working well again, I'm guessing that I was reading things incorrectly.

I had also adjusted the clutch prior to the motor swap, and while that didn't fix the issue, I've noticed that after getting that new motor in, the adjust must have been needed, because the shifting on this machine is the smoothest I've ever felt it. (I've actually only owned the machine for a year, but have been riding it for 4-5. I bought it from my dad so that he could upgrade to a Rubicon last winter.)

Thanks again for the suggestions folks.
 
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