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I've got a question for you if you know of anyone who has experience this problem. I've read through every forum on this and it seems like I can find a specific answer. I've watched countless videos and am not having any luck.

I have an 04 Foreman that only upshifts and downshift ONCE. I can manually move through the gears without the shift motor. Once I put the shift motor on, it tends to bind and does not return to the "neutral position" of the gear shifting. In other words, it seems as if the gearshift return spring (15) is not doing its job. I did replace that spring but it did not solve the problem. I replaced the motor and that did nothing either. I compared the motor on my old rancher and it does not seem the Rancher is as "durable" as the one for the Foreman. You can turn the Rancher motor by hand quite easily. It's almost like the poles on the Foreman motor are a few degrees off or maybe it's just causing too much resistance (too strong) to allow the return spring to do its job. I've read a lot of posts that say the screw (30) is loose but I checked it and it was fine. I took everything apart (to replace clutch and timing chain) and inspected every component (labeled in picture). Nothing is worn or cracked. I did put the screw back in with Loctite and torqued it properly just so you know I didn't make an amateur mistake.

I don't want to give up but am clueless what might be causing this BINDING issue. Please let me know if you've heard of anyone else that may have encounter this problem.

Thanks for reading and commenting.


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Possible cracked magnets inside of shift motor -have you checked for that? Its fairly common
Have you tried loosening bolts on shift motor to see it confirms that it is binding/too tight
-is gasket in place?
 

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Yeah. That's why I said "I replaced the motor and that did nothing either". I made the mistake of taking it off with the Allen bolts and it was at the moment I knew I messed up. lol. I know, it's embarrassing but I guess I wasn't paying attention. I read somewhere where a guy did the same thing and said F it and replaced the motor. I don't feel that bad because I wasn't the first. It's not a total loss as motors aren't as expensive as other things. Like I was saying, "Once I put the shift motor on, it tends to bind and does not return to the "neutral position" of the gear shifting". And yes, I put everything back together correctly including the gasket. I'm assuming you meant the funny shaped O ring (item 3).

Thanks for taking the time out and responding. I really do appreciate it.

Todd
 

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Yeah. That's why I said "I replaced the motor and that did nothing either". I made the mistake of taking it off with the Allen bolts and it was at the moment I knew I messed up. lol. I know, it's embarrassing but I guess I wasn't paying attention. I read somewhere where a guy did the same thing and said F it and replaced the motor. I don't feel that bad because I wasn't the first. It's not a total loss as motors aren't as expensive as other things. Like I was saying, "Once I put the shift motor on, it tends to bind and does not return to the "neutral position" of the gear shifting". And yes, I put everything back together correctly including the gasket. I'm assuming you meant the funny shaped O ring (item 3). Thanks for taking the time out and responding. I really do appreciate it. Todd
I had a problem with my ‘98 Foreman and cleaned and re-lubricated the shift gears to no avail. I determined that the shift sensor wasn’t working and replaced it. I haven’t had any further issues. I got the sensor on Amazon for about $16 versus $85 for an OEM part. Happy about price and outcome. This seems to be one thing that you didn’t evaluate. You can test the sensor using an ohm meter. Good luck Brain
 

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Yeah. That's why I said "I replaced the motor and that did nothing either". I made the mistake of taking it off with the Allen bolts and it was at the moment I knew I messed up. lol. I know, it's embarrassing but I guess I wasn't paying attention. I read somewhere where a guy did the same thing and said F it and replaced the motor. I don't feel that bad because I wasn't the first. It's not a total loss as motors aren't as expensive as other things. Like I was saying, "Once I put the shift motor on, it tends to bind and does not return to the "neutral position" of the gear shifting". And yes, I put everything back together correctly including the gasket. I'm assuming you meant the funny shaped O ring (item 3).

Thanks for taking the time out and responding. I really do appreciate it.

Todd
I did the same thing but with a bit of patience and finagling I wasn’t goin to be beat by my mistake. I carefully reinserted the brushes and using some home made holders I was able to reinsert the armature. I broke it and was determined it wasn’t going to outsmart me. Shift motor works like a new one.
 
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