[ae1103]

Ok So first post,

I have a 2002 Rubicon TRX500FA which would not shift through the gears, and when I ran the codes I ended up getting a code 6. I replaced the angle sensor (new part tested good on an ohmmeter). Angle sensor was pre-loaded according to the manual.

Start-up the atv no longer flashing and continuous "N" appears on the screen. I start the set-up procedure idle for 30 seconds in neutral then roll forward 5 feet in Drive. Says to make sure continuous N changes to D. This doesn't happen ATV drives, but thinks its in neutral.

Go ahead with rest of procedure and shift motor runs after the up down up portion, but then the set-up fails at the very last second. and I get a constant blinking --. I believe this indicates failure of Initial set-up procedure.

turn off key and constant neutral light returns.

 

[ae1103]

Any help figuring this out would be appreciated. Thanks in advance.

 

[Jeepwm69]

I've had to go through that setup procedure several times to get it right.

But, I'm wondering if maybe your old angle sensor wasn't bad, but if instead you just have a bad connection or loose/broken wire.

I assume you have the factory service manual since you said you were following the directions in your manual.

Have you tried unhooking the battery for a bit, then reconnecting? That's worked at times on my father in laws Rubicon when the electrical issues pop up.

Welcome to the forum.

 

[ae1103]

Thanks for the advice. I'll check the old angle sensor tonight and see if it really was bad. I will also try what you suggest with unplugging the battery and going through the set-up procedure again.

Could the ATV not recognizing that it is moved from Neutral to Drive cause a failed initial set-up procedure?

Also, the procedure states that i should hear the shift motor after throttle open closed open portion of the set-up. The shift motor starts right after I do the up down up on the gear selector. Right now I'm chalking this up to a typo in the procedure.

 

[Jeepwm69]

Not a typo. Something isn't right. You have to do it exactly like it says, and in a fairly rapid but steady order or it doen't take.

 

[ae1103]

Ok so I completed the initial setup which seems to have taken

The ATV now shows no codes but shows a constant neutral regardless of if it’s in reverse or drive runs great but only goes like 17 mph. It will not shift gears but I think that’s because the computer thinks the atv is in neutral. Would this stop it from shifting through gears?

 

[ae1103]

Reading a little further into the service manual I believe the issue falls under the not detected by ECM. Looks like it's most likely a faulty gear position switch or faulty ECM. or loose conectors between these two items.

 

[Jeepwm69]

Yes, I'm surprised it will go at all. Normally when a Rubicon can't figure out what gear it's in it will sputter like a rev limiter has kicked in.

There's a gear position switch on the back of the motor. Part #5 in this schematic. I'd look at that closely.

https://www.partzilla.com/catalog/h...fourtrax-foreman-rubicon/rear-crankcase-cover

 

[ae1103]

Got it working last night at least for the most part. I got it off a guy for really cheap because it had known issues. He had bought it from someone else to fix up and never gotten the chance. It turns out at some point in its life somebody unplugged the gear position switch and grounded out neutral to the engine. I plugged it back in and everything now seems to work. Drove it around last night and got it up to about 50, which i believe is about right for this ATV.

Reverse wasn't great anymore but I think it is just a bad connection since the connector is very corroded. I ordered a new GPS so hopefully that will correct the reverse issue.

Thanks again for the help

 

[Jeepwm69]

There's a microswitch on the shifter that will make it misfire in reverse if it's not making a good connection.

Glad you got it fixed!