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Discussion Starter #1 (Edited)
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?

Thanks.
 

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You use OEM parts or aftermarket stuff? The aftermarket Chinese stuff is garbage. Rubicons are very finicky. You pretty much have to use OEM parts or they won't work.
 

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what kind of hours and mile on it? plowing is hard on them, if lots of hours and miles it may need a rebuilt, it should have a new style oil pump installed and check the hondamatic to make sure it is good..
 

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Discussion Starter #5
My apologies for not responding to this thread or posting any other information about it. If I find a fix, I like to post that to end a thread properly. I think it's the respectful thing to do.

Anyway. I haven't had time to look at this in the last month. But hopefully I am going get back at it this week.
I do not believe the transmission itself to be the issue. I still think this is an electrical problem....but I have been wrong before.
 

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all of the oil pumps have been the new style ones for quite a while, 2001 to 2004 had oil pump bypass problems, they stuck open while cold and would not close when oil warmed up and thinned out causing low oil pressure that in turn burned up the hondamatics. does the unit have lots of miles and hours from snow plowing?
i would check the oil pressure before doing lots of repairs. the honda shop manual has very good troubleshooting section. here is a link to a shop manual if you do not have one.

https://drive.google.com/drive/folders/1eqVb5JW5em4PBbDrgHsRbhFKH5rFr75l?direction=a
 

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My TRX500FM1 2017 is randomly shutting down at idle and low speeds, worsening now to include when ran under heavy throttle. kill switch smelled burnt ,resistance high. replaced , checked and swapped relays, cleaned tank, no positive change. Fuel pump? PGM-FI unit? Injector? anybody else seen this? NO CODES STORED!
 
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