[MOfarmer]

I'm not out of the woods yet, it is acting up again. It worked well for a few rides and then starting kicking out of gear, not shifting, difficult to get it into neutral, etc. I am thinking I will replace the angle sensor. Just thought I would update that it was not as simple as it initially seemed.

 

[Rocketman5144]

There is an 8mm shaft coming out of the front of the motor, goes through the shift motor gear assembly. Put a 8mm wrench or socket on it and try to shift it up and down. If that works than your problems are electric. If that doesn't work than you have a mecanical problem. There is a pin screwed into the middle case that the shift mecanism indexes off of to return to it's center position. This pin can brake and the shift shaft never centers it's self or goes back to "home" position and it causes shift problems like you discribe. Sometimes it works sometimes it doesn't.

 

[Rocketman5144]

Number 20 in this diagram is the part I'm talking about.

Honda ATV 2016 OEM Parts Diagram for Gearshift Fork (1) | Partzilla.com

Buy OEM Parts for Honda ATV 2016 Gearshift Fork (1) Diagram

www.partzilla.com

And if it is your problem you are in for major tear down

 

[Grass Roots Ranch]

Thank you @Rocketman5144 I replaced the angle sensor, put a brand new battery in it, and still have the same issues. Sometimes I can get it to work and shift like normal, other times it will not go past second. Every time I turn the key to the on position, it won't show neutral on the display - always just a solid dash (no blinking). I can use the ESP mode to get it into neutral and started but it usually takes a few tries.

I will try that manual shift shaft and see if I can move it. Thanks for your help.

 

[Grass Roots Ranch]

There is an 8mm shaft coming out of the front of the motor, goes through the shift motor gear assembly. Put a 8mm wrench or socket on it and try to shift it up and down. If that works than your problems are electric. If that doesn't work than you have a mecanical problem. There is a pin screwed into the middle case that the shift mecanism indexes off of to return to it's center position. This pin can brake and the shift shaft never centers it's self or goes back to "home" position and it causes shift problems like you discribe. Sometimes it works sometimes it doesn't.

I can get it to shift one position up or down, it is supposed to turn more than that? With the key on, the screen will show N or 1 at the first movement but after that it reverts to dashes. Any thoughts? Thank you.

 

[Grass Roots Ranch]

I can get it to shift one position up or down, it is supposed to turn more than that? With the key on, the screen will show N or 1 at the first movement but after that it reverts to dashes. Any thoughts? Thank you.

The error code is 23. I have the service manual and have worked through the troubleshooting for the most part I think.

 

[Rocketman5144]

I can get it to shift one position up or down, it is supposed to turn more than that? With the key on, the screen will show N or 1 at the first movement but after that it reverts to dashes. Any thoughts? Thank you.

You may have to rock it back and forth a bit, or jack the rear wheels off the ground and turn them by hand, but yes you should be able to get it to shift through all the gears, all the way to 5 and down to reverse. If you can't something is wrong internally.

 

[Grass Roots Ranch]

OK thank you, I can try that.

 

[MOfarmer]

Ok I have gone through the steps that Rocketman5144 suggested and here it what I am getting. With the machine jacked up I can switch up and down thru the gears with the ESP mode, sometimes it will show 1st then if I shift again may show 3rd, continue shifting with thumb shift and can go up to 5th and back down to N, the screen occasionally shown dash line otherwise will show what gear it is in, I sometimes have to turn the key on and off to get it to cycle. While using the wrench starting in N I can shift into gear but the shaft will not return to the middle position, using the gear selector (thumb shift) it will return to the middle position when shifting up and down. Based on this it appears I have an internal transmission problem... any thoughts?

Thanks

 

[Rocketman5144]

Ok I have gone through the steps that Rocketman5144 suggested and here it what I am getting. With the machine jacked up I can switch up and down thru the gears with the ESP mode, sometimes it will show 1st then if I shift again may show 3rd, continue shifting with thumb shift and can go up to 5th and back down to N, the screen occasionally shown dash line otherwise will show what gear it is in, I sometimes have to turn the key on and off to get it to cycle. While using the wrench starting in N I can shift into gear but the shaft will not return to the middle position, using the gear selector (thumb shift) it will return to the middle position when shifting up and down. Based on this it appears I have an internal transmission problem... any thoughts?

Thanks

Have you got a service manual? They can be found online and downloaded. Get one and start reading. At this point I think you are going to have to tear into it to find out what is wrong. I think I posted a link to the parts diagram with the shift mechanism and the pin that I think is probably your issue.

 

[Grass Roots Ranch]

@MOfarmer I have a PDF service manual for 2014 to 2017 TRX420 models, let me know if you need it and I can see if there's a good way to share it with you.

@Rockerman5144 is there a pre-load procedure for the angle sensors on the 2016 model? There is nothing in the service manual for this - just says to install it. I put a new angle sensor in and it didn't fix my problems, called my dealership and they said it needs to be preloaded by putting it on upside down and twisting into place, but this doesn't seem physically possible with the layout, I am wondering if that is a procedure for a previous year model. Anyway, I did take the new sensor out and mess with it a bit and turn the metal half moon inside a bit, when I re-installed it that transmission works a lot better but still has issues at times. It seems to be between 2nd and 3rd. Sometimes it will work completely normally, turn it back on 5 minutes later and will act up.

 

[Rocketman5144]

I don't know of any pre load procedure. Just line it up and install it.
All that sensor does is give feed back to the computer that when you or the computer tell the shift motor to shift the transmission that the shift shaft actually moved.

 

[MOfarmer]

Grass Roots Ranch I downloaded a service manual yesterday and just began to dive into it. In the troubleshooting section one of the first thing it recommends is to troubleshoot the electric shift motor, I'll pull and take a look. When the problem started I had used it and the next day the problems began at startup, not like it occurred doing use, still hoping it's electric vs something mechanical internally. Grass Roots Ranch thanks for the offer, I'll keep posting.

 

[MOfarmer]

Tore into mine today and found the gearshift return spring pin was broke off #18 in the parts schematic link above. I decided to try and make the repairs without pulling the motor and was able to get to everything without too much trouble. Took off the fenders, skid plate, loosened up the front differential..for the most part wasn't too bad. I have ordered parts and we'll see in a few days if it fixes my issues. I've attached a few pictures for reference.

 

[Rocketman5144]

Take a look at the flat plate that retains the ratchet mechanism, just to the right of your index finger. On mine it had become deformed and had a burr on the tab that goes into the ratchet.

 

[MOfarmer]

Will do, thanks

 

[Joe Knight ATV Sgroi]

Tore into mine today and found the gearshift return spring pin was broke off #18 in the parts schematic link above. I decided to try and make the repairs without pulling the motor and was able to get to everything without too much trouble. Took off the fenders, skid plate, loosened up the front differential..for the most part wasn't too bad. I have ordered parts and we'll see in a few days if it fixes my issues. I've attached a few pictures for reference.

Did this fix your issue? I hope you got it working correct again.

I am currently working on a Foot Shift Conversion Kit, I should have the prototype complete in a week. If anyone is interested in this let me know and check out our website for updates.

Honda ATV Manual Actuators, Shifters and more

Honda Foreman and Rubicon Sure 4 Manual Actuator with Tank Lever or Upgrade Side Shifter. Eliminate all those annoying electronic actuator issues once and for all!

sgroiinnovations.com

 

[Jerijol]

Hi.
I have the same issues on my 2016 rubicon.
Replaced the angle sensor and the shift motor still doesn't shift and the gear indicator shows a "-" on the display.
Would appreciate any ideas

 

[Fkc3]

I'm not out of the woods yet, it is acting up again. It worked well for a few rides and then starting kicking out of gear, not shifting, difficult to get it into neutral, etc. I am thinking I will replace the angle sensor. Just thought I would update that it was not as simple as it initially seemed.

I’ve delt with the same issues over & over take out gears cleaned etc., replace angle sensor, will replace shift motor next(seems weak), after that I’m bypassing all sensors with a es computer bypass kit.

 

[BrianDolata]

I had a 2016 rancher 420es model. I had the issue of the machine going into reverse but not back up again so I had to turn it off to get it into neutral. I tried to shift into 1st sometimes it did sometimes it did not. I took it to Power Sports in Kaukauna WI. The mechanic new right away what is was when he looked into the side cover of the engine with a camera and saw a bolt had fallen out along with a spring. From the factory they did not tighten the bolt enough to stay in place. The bolt holds the return spring that puts the shifting into a neutral kind of phase while driving in gear. when you hit the upshift or downshift you need that spring to return it back into the neutral to shift it again. it cost me $1,060 to get it fixed. You need $20.000 for parts and e a side cover gasket and some thread locker to put the bolt back in and the spring back onto the bolt . It is a stupid thing to deal with I know.