Merit

Hey Sandra, It could be anything really it all just depends, I see this was an issue prior to you using the grease as was my issue but it would come and go. Best thing to do is to test each item mentioned above Angle Sensor, Shift Motor, Wire harness testing. Thanks!

Update. After going back through the steps above and adding a few steps I found that the shift motor was having an issue with the armature/communicator of the motor. I followed the mentioned steps in this video here to validate the motor correctly. Doing this, I found that the motor was bad even though it was working once plugged up to a battery. Resolution = Buy a new one. Purchased one online for about $50 here but your results and preference may vary. After replacement of the shift motor I found that it would shift up properly but not down. After doing the wiring tests I concluded that the shifter wires on the downshift had an issue and I replaced the electric shift selector/switch found here. Once installed it shifted perfect up and down with no issues and all my issues are resolved. Final thoughts?!?!?! It pays to research and ask people who know or have been there so you don't go crazy and run in circles. I originally thought that I was about to replace the ECU but thankfully that wasn't the case here after taking the time to seek proper advice. I did find out that the ECU on my ATV is very sensitive and if it reads anything outside of it's normal range it will shutdown the entire function inside the ECU in order to keep from damaging anything else. This can trick you into thinking that it an ECU issue when in fact it's not the ECU at all. Thanks for all the help!

I did the majority of this but not in the exact detail laid out. I'll go back through everything mentioned above and report back my findings. Good info to have on each specific area. I didn't mention in my original post but the Battery has been replaced with a new one.

Can you elaborate (Gear Area). Shift motor/gears? Yes. Final Drive? No Front Diff? No.

Yes, I did re-pack with grease as the old stuff was terrible. It dose and I did adjust it per the specs on the manual- Counter-Clockwise until you get tension and then back off a 1/4 turn if memory serves me right.

" Have you tested the shift switches? I've had some that passed the test yet was dirty enough to cause issues. Most of them I could take the left handlebar switch apart and just clean them with electrical cleaner to get them working again. " Yes, but only the down-shift as the up-shift was working. After pulling the push button apart I did notice a bent spring but I chalked it up to just years of use. Bent it back as good as I could get it and put it back togeather. Thanks!

Evening All! New to the forums here, My name is Chris and I'm looking to get some input on here as to my issues but need to provide some backstory so that you can see the full picture. I've searched the forums but haven't seen anything that matches my issues with the bike not shifting properly. Purchased an 08 420 Rancher FE/ES back in 2013 and it's my first purchase. Purchase was for hunting as I was apart of a hunt club at the time. I had intermittent issues with it shifting over the next year or so if water (possibly splashed up as I didn't really pay attention) was involved. Ex: Crossing a small creek and water barely making halfway on the tires. Note: Tires are 27'' Swamp Witches on SS rims. I could let it sit and at times found water in my shift motor connector so I would dry it out and would start back working. I started using dielectric grease on all the connectors in hopes that a splash wouldn't leave me stranded (Found out later that I had no shift tool under the seat) or stuck in one gear. This has only happened a few times but has gotten worse over time and now won't shift unless you do it manually. I use to live out in the country and had a rat or mouse chew on my wiring harness right at the ECU. Never broke the wire just chewed off the plastic sheathing of the wire so I taped it up with electrical tape until I could address it later. I was still drive-able and shifted gears just fine unless it got wet like it normally would. Between then and now it quit shifting properly, I quit riding it as much and would only let it run for 20 -30 mins a few weeks at a time to keep the battery up. The other part of not riding it was because It would shift up but not down and I had to do it manually without a shifter and now it won't shift at all. So today I replaced the angle sensor and it seemed to work but it would only do the shift up and not down. After checking all the connectors and testing to fix the down shift as the manual says to at some point I must have had the shift motor connector on the front of the bike disconnected when I turned the key on and it start going back to what it was doing...Just blinking a code and not shifting at all. I connected it back but its still acting like it has the same issue as before replacing the angle sensor. I can select all gears manually on level ground but have had to rock it at times for a gear to catch. Not sure of that is normal or not but thought I would mention it. What I've done so far: 1. Replaced angle sensor - Starting somewhat working then quit after trying find why it wouldn't down shift. 2. Per the manual - tested and check the harness wires and everything seems to check out just fine. 3. Thought that the chewed up wires was to blame but I've cutout the bad part of the wires out and soldered in a new one with heat-shrink tubing. 4. Check the shift motor- taken apart cleaned the communicator and verified that it works with 12v direct line to battery, Reversed the leads and it works. Also checked the resistance and it checks to be good. (Note: I didn't rotate the motor while checking resistance but will try this when I can. Not real sure what it should show but I'm sure it's posted somewhere about that. 5. Reset DCT to clear memory. Still not working. Code on it before angle sensor replacement was 23-1, 2 long blinks and 3 short blinks, Code on it now is 24-1. 2 long blinks and 4 short blinks. Testied what it says to test given the current code and eveything checkd out good. Am I missing something? Nothing that I've tried from the manual helps. Anything else I can try? I don't want to buy parts just to throw at it to see if its going to fix it or not. Thanks in advance!

Evening all, My name is Chris and thanks for the invite.