I have what I believe is a 2005 Honda Rancher 450 4x4 with manual shift (please tell me if this doesn’t even exist cause I may be wrong that’s what I was told it was) but it is stuck in reverse. I absolutely cannot get it back into neutral. I pulled so hard on the foot shifter that I actually broke the thing off. So now I definitely cant Shift it. The fact that it is so hard to shift makes me worry I have maybe a gear in the transmission stuck...does this sound like a problem where I will need to dig into the transmission to look for problems? The electric shifter does not work at all on this four wheeler and I dont want to fix that. I just want it to shift normal again. What should my first step be?
I am in the middle of a Honda 450S 1999 model currently for the same issue. First thing to do is get the factory service manual and study it. If it is like the one I had to tackle for this problem, the engine will have to come out. Once again get the manual. Be aware that the manual jumps around a little and is had to follow for DIY person. In that event it helps to purchase the Clymer manual. They are a little more DIY oriented.
What I suspect you will find is the shifter plate buried under the front cover has snapped in two pieces. It will require that you pull the front and rear cover off once out of the machine. When you pull the front cover, It is likely you will find the broken part I am talking about. Be careful of all spacer washers. The shifter plate can be replaced without pulling the clutches out but it takes 2 people. 1 has to slowly feed the shifter long shaft through the case from rear to front has you align the shift components. It can be done, but it is tricky. Once all the parts are aligned, the cover can be put back on. Like I said, get the books.
All parts can be found through Cheap cycle parts .com. The parts diagrams are helpful also, so print them off. There is no repairing this in the chassis, it is hard enough to do on the bench.