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Posted by: homer
The switch under the hand brake quite working on my 650. The brake light wasn't working also. Seems like the start in gear would work if I used the foot brake, but can't remember for sure. I know that there was several of these switches went out on the 650's.
Posted by: ourcat
our 2002 cat 300 4x4 did the same . we checked 2 see if the rear brake lit up when we applied the hand brake. we noticed that the rear light was staying on after the hand brake was released .what we did was we sprayed some lubricant around the master cylinder where the hand brake hits the plunger to activate the brake ,the plunger was sticking and now its free and our start in gear works again. good luck .
Posted by: Catterman
Hey guys, I was out moose hunting last weekend (no luck yet) and had some problems with my start in gear feature. It would only work about 1/2 the time, otherwise I had to put her in neutral and start it up. Not that big of a deal, but I really like that option. Before I dig into the problem do you guys have any idea where I should start? I am still under my two year warantee, but with the $50 deductable I am sure I fix it myself.
Posted by: Catterman
Thanks Kylersk for the fast responce, I will check it out.
Posted by: Catterman
Man, looks like this could be some work, why couldn't you guys just tell me that all I had to do was tighten a bolt and that would fix the problem! BR>
I will check it out this weeked, thanks guys for the help!
Posted by: Catterman
Thanks for the responces guys, just got back from using the ATV all weekend and the start in gear worked everytime. I did mess with some wires and whatever before the weekend so maybe it was just something small. I will look more into it if it happens again.
Again, thanks for all your responces!
Posted by: Kylersk
There's gotta be a switch somewhere that senses if you have the break depressed. I'd look for that.
Posted by: Kylersk
Also, from reading my service manual, there should be a Start in gear relay. Directly from the 650 manual, it may or may not help you:
Neutral Start/Front Drive Actuator/Start-in-Gear/Differential lock Relays.
The relays are indentical plug-in type located on the power distribution module. Relay function can be checked by switching relay positions. The relays are interchangeable.
NOTE: The relay schematic is embossed on the relay housing for testing continuity.
NOte: The module and wiring harness are not a servicable component and must be replaced as assembly.
Posted by: Kylersk
I'm just guessing, but if it's the brake switch, your brake lights wouldnt work when you couldnt start the bike in gear.
Posted by: arcticcop
My 650 did the same thing while under the 6month warranty. They had to replace some type of harness that ran to the brake light, the foot pedal, and then to the hand brake to tell the bike the brake was depressed to allow it to start in gear. They told me the wiring ran down the frame so he had some plastic off and possibly the tank, or so he said??? It was a comon problem, the harness was on back order at the time my bike was down like a month but that was in February or March of 04. I hope this helps in some way! IT is a handy feature so good luck!
Posted by: weez440
same thing happened to my 500i and what it turned out to be is for some weird reason i had to pull the handbrake in harder so try that before you pay the 50 dollars cause i actually brought mine to the shop not knowing and he said i had to just pull hard on the brake and it worked fine after knowing that
Posted by: catmax
on the right side of quad there are two diodes in the harness. if you look behind the plastic about even with the engine. they plug in simiar to a fuse. on a friends 03 400i that wouldnt star in gear he had to replace one of these. odd thin was he could replace either one with a new one and it would start but with the two originals it wouldnt. hope this helps.
Posted by: catmax
the part # is 0486-029
Posted by: DiskDoctr
My dealer told me on the AC 500 that the start in gear was a simple link to the brake light instead of some complex mechanism.
I asked this before purchase, I like to know these things.
Make sure the tail light is coming on with your handbrake...
Good luck.
-JC
