2006 Foreman S Transmission Problem - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
Reply
 
LinkBack Thread Tools
Old 06-15-2009, 03:43 PM   #1 (permalink)
Honda Rider
 
Join Date: Jun 2009
Posts: 12
Default

Greetings to all on this forum! My first post here, and I'm really hoping someone has encountered the problem I'm having and knows of a fix. I've spent 5 or 6 hours online today looking for an answer. . . with no luck yet including at this forum. I'm going to add as much info as I can to this post, so please bear with me.

I purchased a used 2006 Foreman S TRX500FM6 from a private party back in November, 2008 with about 5700 miles on it. I bought it with no owners or service manual. I brought it home and rode it a little bit until we got snow, and then stored it in the garage for the winter. Only ran it in the snow once in the late spring, and that basically in the driveway and really just to get a feel for it.

Not long after I bought it, I noticed that the machine sometimes had trouble shifting from Reverse to neutral and, although less often, also had trouble shifting from from 1st to neutral. Felt like the lever would bind up and not complete the motion- like it was "sticking" or something. I tried to not bang on the pedal too hard, and just keep "coaxing" it until it would shift- which it always eventually did.

This past weekend, I had a trailer hooked up to this Foreman and was hauling firewood. I've been doing this off and on for the past several weeks without anything unusual happening. Anyway, the tongue of the trailer got hung up on a little hump in the trail, so I put the ATV in reverse to back up a little and get a run at the incline, then shifted to 1st and pulled forward. I didn't get the trailer free, so I repeated this several times. In the course of trying to free the trailer, I noticed the transmission was starting to act up again and was having trouble getting from Reverse to 1st. In 3 or 4 attempts at "rocking" the trailer free, I had the "sticky lever", trouble- shifting problem, and noticed that once or twice the machine actually appeared to skip neutral and went straight from 1st to Reverse. Finally the machine wound up in 1st and would not shift down to neutral or Reverse again.

I shifted up to 2nd to confirm that the transmission was working at all, and it shifted up just fine but still would not shift back down. I then thought maybe I had to go up to 5th to sort of "realign" things, but once in 5th it still would not shift down. I eventually had to just shut the machine off and take stock.

I then towed the Foreman back to my garage to get a better look at things. I tried rocking it back and forth while shifting down, and after 20 minutes of trying did get it to shift from 5th to 4th. I have not been able to get it to shift down any further, though, and I can't turn the engine over since it's not in neutral. The shift lever is still acting like it should- clicks when pressed and returns to center when released. It's not "dangling" or anything like that. I haven't tried shifting up again, since it took so much work to get it down to 4th in the first place.

I also want to mention that while I was poking around the left side of the motor, I discovered a small rubber hose with a brown or black plastic cup hanging down to the bottom plate. I'm not sure what it is, it smells of gas but does not seem to be leaking it. It comes from the bottom of the first part that the fuel line enters after leaving the gas tank- something mounted high and behind the engine. The plastic cap on the end is a little busted up. Can anyone tell me what that hose is and if it's supposed to connect anywhere? I searched for quite a while and didn't find any obvious connection point.

Obviously my first question is, does anyone know anything about this issue? Is there a way that I'm overlooking to get the machine to shift back to neutral? I would like to be able to turn the engine over to see if the linkage is just stuck or something. Is there a way to get the engine started while it's in gear?

My other question is regarding a service manual. I like to work with Haynes manuals, but they don't seem to offer one that covers this model. I've seen links to other manuals here, but am wondering if Haynes has one since I'm used to working with them.

Any help would be greatly appreciated. I can't seem to find anyone who's seen a Foreman do this, and am starting to worry that there's a major problem here. Thanks in advance. . . .
james011370 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 06-15-2009, 04:06 PM   #2 (permalink)
Honda Lover
 
desert dawg's Avatar
 
Join Date: May 2007
Location: Utah
Posts: 333
Default

Wow,
First off... Welcome to the forum,

I think the small rubber hose with the gas smell is just the carb over flow drain line,
normal , no problem.

The shift problem from Rev. to N and from N to 1st gear is a common problem if your engine idle speed is set too high.
try lowering the idle speed using the black thumb screw on side of carb and see if it helps.
maybe you will get lucky..
__________________
*** 06 Foreman 500 ES 4X4 ( Olive) ***
* NGK Iridium (5464) /Quick Reverse *
* Gorilla XT 2.5 / Blue Synthetic *
* Center Headlight Assist Toggle *
* Jetted to #155 ( Rocky Mountains) *
* Handlebar GPS & Mount *
* Pioneer Rear Storage Box *
* Rear Rack Tool Mount / Gun Rack *
* Koplin 3.2 / 1 1/4 gal. Fuel packs *
* Duro Power Grips (25's)
* UT Piaute ATV Trail Decal 07 *
.45 cal Bullet Hole Decal
Wife loves her 06 Yellow Rancher TE6 ( ES)
desert dawg is offline   Reply With Quote
Old 06-15-2009, 04:56 PM   #3 (permalink)
Honda Rider
 
Join Date: Jun 2009
Posts: 12
Default

Thanks for the welcome, Desert Dawg. Sorry for the long first- time post but didn't want to leave out any necessary info.

The idle setting may be the issue, but as of now the machine is stuck in 4th gear and won't shift down- so I can't turn the engine over at all. The primary task right now is to get it back to neutral so I can get the engine started.

Thanks for the tip on the dangling hose. Someone else also mentioned that it was probably the carb overflow, so I'll quit worrying about that one now.

MN
james011370 is offline   Reply With Quote
Old 06-15-2009, 05:07 PM   #4 (permalink)
Honda Lover
 
desert dawg's Avatar
 
Join Date: May 2007
Location: Utah
Posts: 333
Default

That 05 and newer foreman will start in 4th gear,, or any gear for that matter...

a little Info.............. ha

Turn the ign key on and pull back and hold the right side handlebar ( front) brake handle.
while holding back on this handle hit the start button, it should turn over and start for you.
try it .
__________________
*** 06 Foreman 500 ES 4X4 ( Olive) ***
* NGK Iridium (5464) /Quick Reverse *
* Gorilla XT 2.5 / Blue Synthetic *
* Center Headlight Assist Toggle *
* Jetted to #155 ( Rocky Mountains) *
* Handlebar GPS & Mount *
* Pioneer Rear Storage Box *
* Rear Rack Tool Mount / Gun Rack *
* Koplin 3.2 / 1 1/4 gal. Fuel packs *
* Duro Power Grips (25's)
* UT Piaute ATV Trail Decal 07 *
.45 cal Bullet Hole Decal
Wife loves her 06 Yellow Rancher TE6 ( ES)
desert dawg is offline   Reply With Quote
Old 06-15-2009, 05:58 PM   #5 (permalink)
Honda Rider
 
Join Date: Jun 2009
Posts: 12
Default

Nope, just ran out and tried it and it didn't turn over. It has only started in neutral as long as I've had it, and I've experimented with that before. I've shut it off in gear a few times before and had to tap down to neutral to get it to turn over. Thanks, though.

MN
james011370 is offline   Reply With Quote
Old 06-15-2009, 09:15 PM   #6 (permalink)
Honda Lover
 
mischievous_james's Avatar
 
Join Date: Aug 2008
Location: pikeville, kentucky
Posts: 262
Send a message via Yahoo to mischievous_james
Default

that is strange. my 08 foreman will start in gear just like dawg said. wonder if something is loose in the transmission hindering the downshift?
__________________
08 foreman 500s (white) kimpex bumpers, gorilla hitch, warn winch,quadrax rear seat, fender protectors. coming soon: wheels, skins, springs.
mischievous_james is offline   Reply With Quote
Old 06-15-2009, 09:18 PM   #7 (permalink)
Honda Red Wing Rider
 
dirty4man's Avatar
 
Join Date: Mar 2005
Location: Central City, La.
Posts: 2,697
Default

The gearshift plate itself could be broke or maybe even the gearshift arm. Try working the shifter by hand, if it's working proper you should feel it trying to engauge, there is going to be some resistance on it from the spring so dont get the two confused.

The clutch cover has to come off to inspect shift plate, the shifter will spring back into place even with the plate being broke. But if the shift arm is broken the shifter will just hand down.

Heres a link with a parts finder, just type in you bike info and it show you every part on the bike. Once you have your info in and it brings up the parts finder, just seach under gearshift drum and it will show you the parts I am talking about.
http://www.polarispartspitstop.com/
__________________
98/01 Foreman 400/450 Halfbreed with to much to list according to the site
dirty4man is offline   Reply With Quote
Old 06-16-2009, 12:27 AM   #8 (permalink)
Honda Rider
 
Join Date: Jun 2009
Posts: 12
Default

Thanks m & D4; input's helping right now.

Checked out the exploded parts view a few days ago. The pedal is operating very much as it did before, so I don't think its the shift arm. I think I'm hearing the trans trying to engage. It still settles in the middle after up or down action. I hadn't thought of the plate, though. I could really use a repair manual, to get a better picture and some terminology. If you've got a recommendation it would help a lot.

The previous owner told me specifically that the machine would only start in neutral, and I have found that to be true so far. I'm also a little confused about how the transmission would be able to work intermitently- like "shift every so often" when I managed to get it from 5 to 4. I am considering the high mileage, though, and am braced for the worse end of the deal, I guess. I'm fairly able when it comes to the old '80s 'yota 22-RE, but these things are clearly different. I really appreciate any ideas that you might have. Thanks again,

MN
james011370 is offline   Reply With Quote
Old 06-16-2009, 11:29 AM   #9 (permalink)
Honda Lover
 
desert dawg's Avatar
 
Join Date: May 2007
Location: Utah
Posts: 333
Default

I am getting close to the end of my knowledge base on your problem.
Here are a couple more things you might try. BTW That mileage is not considered
over the limit too high, Its a HONDA. Its justs gettin broke in ... lol

Pull the pull start rope and see if the engine turns over, it should even in gear.
if not, might have a starter locked up in or a froze up engine.

How is the engine oil level ? Tyranny lubes by engine oil.

Jack up rear end of bike and make sure its in 2 wheel drive, see if you can turn the rear tire at all, might be some torque on them. reason it will not shift.

Finally try the start in gear procedure again ... key on, right brake handle back, and this time use the pull rope starter, ( by pass the starter button system.)

good luck...............
__________________
*** 06 Foreman 500 ES 4X4 ( Olive) ***
* NGK Iridium (5464) /Quick Reverse *
* Gorilla XT 2.5 / Blue Synthetic *
* Center Headlight Assist Toggle *
* Jetted to #155 ( Rocky Mountains) *
* Handlebar GPS & Mount *
* Pioneer Rear Storage Box *
* Rear Rack Tool Mount / Gun Rack *
* Koplin 3.2 / 1 1/4 gal. Fuel packs *
* Duro Power Grips (25's)
* UT Piaute ATV Trail Decal 07 *
.45 cal Bullet Hole Decal
Wife loves her 06 Yellow Rancher TE6 ( ES)
desert dawg is offline   Reply With Quote
Old 06-16-2009, 12:03 PM   #10 (permalink)
Honda Rider
 
Join Date: Jun 2009
Posts: 12
Default

Hey Dawg, good morning.

Okay, I checked the oil level first. Oil is a light brown color, not milky or muddy. Wheeler's been sitting level overnight, so the cold level on the stick reads above the max marker when first removed. When wiped and dipped back in (without threading the cap) it reads dead- on max level.

Jacked up the back end and set the switch for 2WD. Rear wheels turn freely clockwise (to the right/reverse) and turn counterclockwise (left/forward) with some resistance that seems in line with being in 4th gear, ie. there's resistance as the piston turns then free until the next stroke. I can smell gas running through the carb when I do this or roll the machine forward.

Tied the right brake handle down, turned the key and set the switch to "run". Tried the rope starter both with and without choke. The engine turns, but will not turn over. The only thing I noticed is that there's a "ping" sound as the recoil starter finishes its stroke. . . as in "<pull> chug-chug ping". Not sure if that's normal as I haven't ever had to use the recoil starter. It doesn't sound menacing, though.

It's sad to say, but I'm feeling a little better that I'm not the only one who's perplexed by this. Of course, that doesn't really take the sting out of a downed Foreman though, either!

Another question re: the previous posts: If I pull that clutch cover off should I expect to see oil. . . meaning should I drain first or have a pan handy?

MN
james011370 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -4. The time now is 04:28 AM.




Powered by vBulletin® Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
SEO by vBSEO 3.6.0