Hey guys. New member, but been reading and using this forums great information for years for troubleshooting as I work on ATV's on the side.
I have researched my issue for weeks now on several different websites, and have only found a couple threads with a similar issue, but the fixed was never posted. 1 ended the thread with "bringing it to dealer", and never posted the fix after.
Anyway, my issue with with a 2002 Honda Rubicon 500. I will give the history that I know and the problem it has now.
It came to me stuck in first gear, D1,D2 and ESP gear flashing, and spudder in reverse (barely moves itself in reverse). The guy said he was plowing snow with it, and it just stopped shifting and starting flashing the screen.
I got Code 5 and Code 6.
I found the shift motor gear was locked up, and the angle sensor bad. A new Angle Sensor was installed and I freed up the locked gear in the transmission, but the issue remained. I found the shifting motor was broken. The magnets inside the shifting motor casing were destroyed. I rebuilt the shifting motor with 2 different motors, and it now functions perfectly.
Battery voltage is good.
Now the final issue. Still getting Code 5.
When I re-initialize the system, the shifting motor will only turn oneway, and it keeps turning until it locks up. And it locks up every time I initialize the system.
I have to remove the shifting motor everytime I initialize the system and use a screwdriver to free it up. And I immediately get code 5 everytime as well.
I am getting 5 volts at the angle sensor too. I was thinking a possible broken wire, but I am getting a meter reading on the 3 wires on the angle sensor connector when I check them to frame ground. Can't remember the resistance readings though.
What am I missing here?
Last edited by Dezz; 05-25-2019 at 08:05 PM.