2004 John Deer Buck Utility ATV 500, 500EX and 500EXT Service Manual, Page 37Get this manual
Clean contact surface and retighten contact screw(s) with recommended torqueGo to next stepWire harness has broken cables? Replace wire harness Isolating washer located on the shift drum is worn andor damaged? Replace isolating washerGo to next stepShift fork(s) is (are) worn out andor engagement pins are damaged? Replace shift fork(s)Go to next stepShift fork(s) is (are) worn out andor fork(s) is (are) damaged? Replace shift fork(s)Go to next stepShift gear(s) is (are) worn out? Replace shift gear(s)
Check engine idle speed (choke in use)Choke is in use and increases the engine RPM? Go to next stepAdjust or repair chokeIdle speed is too high? Adjust idle speedGo to next stepCheck indexation of shifting lever on vehicle side panelLever is not aligned with vehicle side panel indexation? Readjust indexation of shifting lever in accordance with side panelGo to next stepShifting lever is bent? Replace leverGo to next stepShifting lever is bent? Replace leverGo to next stepCheck shift shaft spline andor shift forks for wear andor damagesShifting indicator switch(es) pin(s) is (are) worn out (no roundings on top of pin)? Replace shifting indicator switch(es)Go to next stepShift shaft is worn out andor shows damaged splines? Replace shift shaftGo to next stepShift drum track(s) andor splines is (are) worn out or damaged? Replace shift drum and damaged part(s)Go to next step