retro

Speed reading again just like the old times, ehh shade....? :-) Its an easy fiix @ChadD, no worries. But verify before you take it apart in case its something else.

He replaced the crankshaft, rear cover gotta be removed to pull that off. :-)

Grab your multimeter and check continuity between wire colors and ground as the manual shows, while shifting through each gear. I think you'll find that the switch pin is turned 180 degrees from where it belongs when you installed the rear cover. Its easy to correct.

Yup, his is still shifting too, so its probably the GP switch wasn't lined up right when the cover was put back on. Its easy to test by using a multimeter before ya tear the back cover off. See the attachment.

Generally, ES bikes didn't break the end off of shift drums. That was an FM model problem.

It sounds like the long pin on the gear position switch was not lined up with the "N" mark on the switch when the rear motor cover was installed. Or that switch or harness connector may be bad? See section 10, page 11 of the service manual.

I would test that first... or look it up in the wiring diagram. Then snip one of those two wires close to the switch. Connect one snipped wire end to relay #30, the other snipped wire end to relay #87a. So in normal operation the mounted switch would still work. But once the relay is energized by the over ride switch #87a would be open circuit. EDIT: Relay #86 would be connected to positive voltage from the override switch, relay #85 connected to ground. OR, depending on how the override switch works, #86 might be connected to fused & switched battery voltage, with #85 getting its ground from the override switch.

I don't have the circuit in front of me, but I imagine if the relay was used to break open either wire going to that switch the circuit would be defeated. Same as if you disconnected one of the two wires from the switch... that switch could not work.

Yup, it looks like the commutator was eroded/arced away by those worn out brushes.

My Rancher used to condense water into the oil up high behind the starter motor too. A homebuilt fan control unit solved that problem by allowing the motor oil to get hot enough to boil those milky films away. I don't think that moisture does any real harm.

Sounds like a good place to use a relay in line with that two-wire gear shifter switch..? The DPDT gear position switch could be used to energize the relay to open that circuit temporarily maybe?

Welcome @Goober

Its great to see ya again @Goober!

We are progged to receive some arctic air tuesday thru thursday, then its suppose to move off east. So this coming weekend might be a chiller for ya's Mel.

I always thought the 6mm screwdriver was only needed to start the initialization process. Once you turn the bars it falls out and isn't needed anymore.... or am I telling folks the wrong way to do it?

Welcome to the forum!

Welcome Brandon!

Welcome jeffo21!

Clemson won again too, 62-17.

Ya that was ugly and lame!

OSU 31, WI, 21 now... totally different looking team in the 2nd half.

Ohio St 7, Wisconsin 21 at the half.

Congrats to LSUs SEC championship!

Thanks for the tip! Got 4 of 'em on the way from rockauto cheap!

Welcome to the forum! Start a thread in the utility section when ya get ready.