I kind of have the same problem with my 05 Foreman 500S. My problem is when I am shifing from 2nd to 3rd it does not want to shift the first few times I go through the gear pattern. I have to reach down and shift it with my hand. After riding for about 5 to 10 minutes it is fine for the rest of the day. It has been doing it ever since I first got it in February of 2005. I took it to the Honda dealer yesterday to get the clutch recall done on it and told them about the shifting problem and they said they would look into it. Should have it back by the end of this coming week and I will let everyone know how it turned out and if they found anything.