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Discussion Starter #22

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Winch controller? When I first noticed it it hadn't rained in a couple of weeks.
Doesn't the wiring go thru the dash module on your model ? Wouldn't be considered a controller or maybe a module for a better term !
You mean the meter?
the dash pod , meter , screen , display or what ever you got on yours , if the neutral light , 4wd indicator , temp light and that kind of stuff is in the "Gizmo" , then may be that is where the problem is
 

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Discussion Starter #25
Doesn't the wiring go thru the dash module on your model ? Wouldn't be considered a controller or maybe a module for a better term !
You mean the meter?
the dash pod , meter , screen , display or what ever you got on yours , if the neutral light , 4wd indicator , temp light and that kind of stuff is in the "Gizmo" , then may be that is where the problem is
Well this one did go upside down in some water a couple of months ago. no sign of moisture in the display.

Kill switch works if I start the bike and then shut the kill switch off. I just can't get the meter to power down, and the bike will start with the key off.

Haven't had time to look at it again. Inlaws left yesterday and this morning I got up at dawn to get all the limbs cleaned up from the two big storms we had late last week.

Will hopefully get a chance to dig into it tomorrow morning early.
 

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^^^ @fishfiles

You said you tried another ignition switch. When you disconnected the old one did the light go out?? I think you said it did not go out.

"Another quick test to do is to put it in reverse with the key off. The reverse indicator light that normally would not come on if the key is off, but if it does come on with the key off, that will be helpful to know because both the neutral light and the reverse light are powered from a common connection within the display meter. So does the reverse light come on with the key off and the tranny in reverse?" Credit to Ktriebol on Foreman Forum. I'm not this smart. :)

Please read the rest of Ktriebol's post. He goes into great detail about how to track down the problem being in the display.

https://www.hondaforeman.com/130-foreman-500/143074-neutral-light-when-key-switch-off-2.html
 

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Is your 500 a Rubicon or an FM? I was looking at the FM diagram earlier, maybe I was looking up the wrong bike? The FA models have two 30a fuses, main and motor. The motor fuse feeds power to a bunch of stuff through harness junction #2.
 

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Discussion Starter #28
Is your 500 a Rubicon or an FM? I was looking at the FM diagram earlier, maybe I was looking up the wrong bike? The FA models have two 30a fuses, main and motor. The motor fuse feeds power to a bunch of stuff through harness junction #2.
It's an FM.

I'll have to look again at Girlsridetoo's link. With the ignition switch unplugged nothing is powered up.
 

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Discussion Starter #29 (Edited)
This morning I went out and messed with this a bit.

Put the 30A main fuse back in. Turned key on. Display lit up, everything worked like it should. Turned key off, display shut down. Leave it for a bit while I go move some wood I cut over the weekend (big limb down from a storm), come back and it's still off

It's ALMOST like it fixed itself, except....the oil change light is on every time I turn the key on. I can reset it, turn the key off, and when I turn the key back on, the oil change light is on again. Likewise, the clock doesn't want to keep time. If I turn the key off, the clock goes back to blinking 1:00. Set the clock, it keeps time until I turn key off, then when I turn it back on, clock is blinking 1:00 again. The meter is crystal clear, doesn't seem to have any moisture in it (would cloud the lens sitting in the heat), but I think this is definitely a meter problem.

I also noticed my dual zone heated grip controller stays on all the time. I can turn it on, and the lights are really bright. When I turn it off, the lights dim but stay on, and the grips still get hot. I unhooked those for the time being. I think the controller for the heated grips must have a short. OR, is it possible I have a ground issue that might be causing my other issues as well.......?

Very strange on the issue with the display coming on with the key off, because it seems to have stopped doing that, and I haven't really done anything to it other than let it sit for a few days with the main fuse out.
 

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It still sounds weird even though it quit coming on with the key off. Maybe a bad ground like you said... maybe water inside a connector somewhere along with a bad ground somewhere else. Might have to take the fenders off to clean and dielectric grease the connectors.

It sounds like the meter has lost backup power since the clock isn't working with the key off. So I'd probably begin the process of elimination at the display connector.
 

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Discussion Starter #32
More and more I think the issue might be in the meter or meter connection.

Went out this morning and turned the key on, neutral light came on, but nothing on the display now at all. I didn't really mess with it, opting instead to take the front fender back off my daughter's 300. Going to get an OEM start/headlight switch for hers, and also need to bleed the brakes again.

Time is so dang limited now I'm not getting much done. I do have two (maybe 3) extra meters in the shop so when I get time I'll try swapping one of those onto the Foreman. This one is snorkeled so going to be a PITA getting the front fender off.
 

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Discussion Starter #33
Pulled out my extra meters early this morning. Have one with 1600 miles on it (09), one with 3500ish on it (07), and another with 7600ish on it (07). The first two are in good shape, the third is rough, but it works.

Pulled front fender, unhooked meter, plugged in an extra. Worked fine. So did my 2nd used meter.

So I took the faulty meter apart. No sign at all of moisture in the housing. Everything looked clean and dry.

The third meter has a busted cover and two of the three mounting bolts pulled out of the back of the case. I decided to see if I could swap the good cases with the innards from the good meter and the cases of the faulty meter.

Two simple plugs on the back of the LCD display and board.

Took it back out to the bike and got nothing. Interesting.

Took the old faulty meter, plugged it into the wiring on the ragged out case, and bam, powered right up.

So basically I have an issue in the wiring, not in the actual LCD display and board.

So for now I've put the LCD display and board back in the good set of cases, with the wiring harness from that busted up meter, and it powered up fine.

Ran out of time and had to get to work, so will button it all back up tomorrow morning.
 

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Wow, I don't see many bad harnesses from Honda. Thats gotta be a rare occurrence, or isn't it? Maybe its common with meters and we never knew... since those harnesses are flexed and twisted constantly with the steering stem? Its great that you had good spare parts so you could find and share the problem with us. But a bummer that it took time that ya ain't got to spare. :)
 

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Discussion Starter #35
Not a big deal. Actually a good thing as I can clean out all the swamp ick that ended up all up in the plastics when I flipped it.

At least the meter I used to fix it was busted anyway, not anything I would have used in its complete state.
 

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Discussion Starter #36
Got the old meter installed with a replacement wiring harness this morning, works great now.

My Heat Demon dual zone controller for my heated grips still won't completely shut off. Took it loose from the handlebars and it's full of water. Guess I need to get that out of there huh? LOL

Also put a new winch switch on as the old one was iffy at times, and when you need a winch, you need a winch.

So now just need to get the heated grip controller dried out, hose everything down good while I have the front fender off, and put it back together.
 
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