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Discussion Starter #1
:icon_eek:

First off - found some great reference material here, looks to be some helpful folks here. I'm located in southwestern Ontario, Canada.

Bought a 2004 Honda Fourtrax TRX400FA a couple months ago. Great price, low km's, but alas there were issues. It kept going into limp mode, flashing the D1 D2 ESP 6 times. I had it into the shop where a friend works, they replaced the angle sensor. From what I can tell, it's a common problem reading some online info.

Now I've got it home, and it's flashing 12 times. They've followed the troubleshooting schematic and cannot figure it out. All leads end with replace the master control box (not technically the right name...sorry). Every schematic ends with the same direction.

My gut feel is I have an electrical issue somewhere. When I start it now, when I turn the key on when the screen flashes after 2-3 seconds I can press the starter button and most times it will start and the constant "N" will appear and all is good. If I don't start it in that split second, it will just start flashing the error code (12 blinks) and run. Right away it goes into limp mode.

I noticed the green "N" light flickers, which makes me think there is a weak signal or electrical issue somewhere. I'd LOVE to put di-grease in all contacts, but most of them have 3 hooks which makes it very difficult to remove them without damaging them.

Thoughts, comments, direction, etc.?

Very much appreciated.

Daemon
 

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When they replaced the angle sensor did they preload it or just install it?
 

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Discussion Starter #4
I have to assume they preloaded it, as we had a discussion about it when I took the machine in. I had removed the angle sensor and cleaned it, applied di-grease, and reinstalled with the preload. Tried the reinitiallization process, and still had the same problem.

My machine used to flash 6 times (angle sensor) and after that it started with the 12 flashes. Funny thing is they had it running without any error codes a few times, but then code 12 started. It's like chasing a gremlin!
 

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Discussion Starter #5
New finding....

I noticed today that the 30amp fuse keeps blowing as well, I've replaced it several times in the last couple months. I assume something is drawing too much energy causing it to blow.

Another thing - it's always going into limp mode now, but if I hold the starter down when it's running, the "N" light will come up on the dash indicating all is well. When I move to reverse or drive, it jumps back into limp mode.

Thoughts?
 

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Discussion Starter #6
More work, more findings....

:icon_ cry:I'm going to figure this out, one way or another.

Today's work:
I took apart as many electrical contacts as I could get at without removing body panels and filled them with di-grease.

I tried to reinitialize the machine with the initialization procedure, but for some reason at step 8, the control motor does not initialize/sequence.

The shop did take it off, inspect it for moisture, and had it running. Now it won't do anything. That's the current dilemma, the control motor will not actuate when reinitializing.

Any comments or otherwise would be greatly apprecriated.

Thanks,
Daemon
 

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Are you getting power into it?
 

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Discussion Starter #8
Hi Saber - thanks for the reply. Not sure how I check for power to it, as the power cord seems to run into the block beside the control motor. Do I need to trace it backwards to the connector up inside the front body and check if connectivity is present there?
 

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The plug that gos to the shift motor is known to have issues. Start there and make sure all the connections are good then try to get a test like in there. somewhere.
 

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Discussion Starter #10
Money pit Honda....

I took apart the shift motor this evening, and found that it would not spin freely. The spline gear going into the motor spins freely. The one on the shift motor was locked up.

I took the motor apart and found that the magnet surrounding the drive was shattered. Ie. the shift motor is seized.

So.....now I guess I need a new shift motor, with no inclination that will actually fix the machine so I can use it.

Any recommendations on where to get one for a good price? From what I've read, they are expensive, and having looked at one inside out, I can understand why.

Thanks,
Daemon
 

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Try bike bandit dot com
 

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Discussion Starter #13
OMG...I'm going to set this thing on fire soon.

So I've replaced the following:
1. Angle Sensor (cleared out code 6)
2. Gear control motor (hoping to clear out code 12).

The POS is still not finding neutral for some reason. When I start it up, it goes directly to the error code. I try the reinitialization procedure and the gear control motor doesn't actuate whatsoever. I'm STILL blowing 30amp fuses for the gear control motor.

WTF is going on with this machine? The thing was working great, the issue was intermittent, now it won't do squat.

Seriously does anybody have any advice on what to do next? Could I seriously have a bad ECM as well!???
 

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Discussion Starter #14
Another finding. I found another way to retrieve codes (Hold down shift buttons, start machine, let go of shift buttons, and then hold them down again for 3+ seconds)
I also have my 4X4 code flashing 4 times when I try that code.

I think my machine is having issues with the position of the gear selector possibly? It never finds N, it just goes right to the 12 flashes on my gear indicator. With the forementioned code retrieval, I get the 12 flashes on teh gear indicator location AND the 4X4 light flashes 4 times.

HELP.....
 

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Discussion Starter #16
Still Code 12, new rectifier, POS Honda still no workie

So, I've replaced the following:
1. Angle Sensor.
2. Shift Control Motor.
3. ECM
4. Voltage Rectifier.

STILL the machine will not exit limp mode. I cannot get through the first part of the initialization procedure because the shift control motor will not actuate.

WTF is up with this HONDA POS?????????????????

All these eroneous codes and I've replaced and done EVERYTHING the manual states to do.

NOW WHAT?????????

Frustrated as hell.:mad::mad::mad:
 

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i know this is a shot in the dark..but..i'll say it anyway..or ask..which ever..just for chit's and giggles..do you think the reason your shifting thingy is shorting out somewhere inside the case ???..causing it to blow fuses..and not go into gear ?..just thought i'd run that by ya :)..sounds like a bad ground inside the case..or somewhere either comming..or going to your shifting motor..worth a shot looking at.
 

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Discussion Starter #18
Oh boy. Well, still no luck. Here's an update - is there nobody who has had the same problem? Code 12 on a 2004 Honda Rancher.
I've replaced the following, or performed the following work - and still CODE 12 flashing.
1. Replaced Angle Sensor
2. Replaced Shift Control Motor
3. Inspected all motor control wiring for continuity, di-greased EVERYTHING.
4. Replaced ECM, still no dice.
5. Tried Ask Question & Experts Answer You ASAP! Name Your Price, Get Online Advice & Help - Just Answer! and they recommended I check the voltage at the rectifier. It was OUT TO LUNCH so I replaced with a new one.
6. Tried ANOTHER ECM, still no dice.
7. Considered setting the damn thing on fire (again).

Still flashing Code 12. I can run it in 4X4, I can run it in limp mode. Machine will not find Neutral, so cannot do initialization sequence.

Any and all (constructive) feedback very much appreciated.

Thanks,

Daemon
 

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I took apart the shift motor this evening, and found that it would not spin freely. The spline gear going into the motor spins freely. The one on the shift motor was locked up.

I took the motor apart and found that the magnet surrounding the drive was shattered. Ie. the shift motor is seized.

So.....now I guess I need a new shift motor, with no inclination that will actually fix the machine so I can use it.

Any recommendations on where to get one for a good price? From what I've read, they are expensive, and having looked at one inside out, I can understand why.

Thanks,
Daemon
try e-bay.
 

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Discussion Starter #20
Try ebay? Thanks - used it a few times to get ECM's. I've already replaced the shift motor, as shown in my post yesterday.

Oddly - I was able to get the machine to run last night with 1 gear forward and it wasn't in limp mode, so the Reverse gear was fully operational. It's been in limp mode for months with no reverse. I did inspect the D/N/R switches which are under the left engine cover. I found one to be broken with likely little to no contact. I replaced the connection, which allowed me to have Reverse again. I'm going to check for continuity between all 3 of them and the ECM wiring harness to ensure I have a signal.
 
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