Hondamatic Troubleshooting
Contents
1. JUNE 2004 the wrench Honda Technician Newsletter The Wrench Special Edition TRX500FA FGA Hondamatic Electrical Troubleshooting Procedures To assist technicians in troubleshooting the Hondamatic system we ve compiled the following troubleshooting proce dures and tips from numerous sources including The Wrench articles the TechLine knowledge base and model specialists Use this resource often to become proficient in Hondamatic service saving your customers and your dealership time and money Hondamatic System Overview The following is an outline of the Hondamatic electrical system construction The output speed reduction ratio is controlled by the angle of the hydraulic motor side swash plate The position of this swash plate is determined by the ECM which uses various pieces of information to send commands to the con trol motor that moves the swash plate arm The signals used to determine optimal automatic transmission output are Throttle opening throttle position sensor e Vehicle speed vehicle speed sensor Engine speed rpm ignition pulse generator e Automatic transmission control motor swash plate angle angle sensor Sub transmission gear position gear position switch R N D L e Control mode and map drive mode select switch D1 D2 ESP e Manual shift range ESP shift switch 1 2 3 4 5 THROTTLE POSITION SENSOR COMBINATION METER IGNITION PULSE GENERATOR FLYWHEEL ANG2. LE SENSOR VEHICLE SPEED SENSOR m GEAR POSITION SWITCH SUB TRANS MISSION iE GEARSHIFT DRUM DRIVE MODE SELECT SWITCH CONTROL MOTOR AUTOMATIC TRANSMISSION UNIT GEAR SHIFT LEVER See section 25 Features of the 2001 2004 TRX500FA FGA Service Manual for a technical explanation of the oper ating principles design construction and operation of the Hondamatic Before Troubleshooting Make sure you have followed all of the steps below before you start 1 Understand and verify the conditions under which the problem occurs e ESP or Auto Does the problem occur only in ESP or Auto mode or in both modes e Function or noise problem Is the problem functional or simply a noise issue Fill outa TRX500FA FGA Troubleshooting Questionnaire see page 4 of this issue Make sure you interview the customer to get a complete picture of the problem occurrence make copies of the attached Questionnaire 2 You must start any troubleshooting procedures with a fully charged battery 3 Check all fuses including the 30A shift motor fuse Troubleshooting Procedures Begin your troubleshooting by determining if the problem is electrical or mechanical Electrical Troubleshooting True electrical problems typically display flashing trouble bars on the TRX500FA FGA the gear position indicator on the meter blinks For non electrical problems see Mechanical Troubleshooting below or refer to t
3. edure refer to the December 2000 issue of The Wrench 2001 TRX500FA Rubicon 16 Tests Code 5 Angle Sensor Circuit Can be caused by a mechanical lock of the swash plate Can be caused by improper initialization e Can be caused by a bad sensor bad voltage output due to poor connection or water intrusion e Perform troubleshooting procedures for Problem Code 5 Service Manual page 23 14 e NOTE If you replace the angle sensor pre load the sensor then perform the initialization procedure Code 6 Angle sensor voltage e Can be caused by a bad sensor bad voltage output due to poor connection or water intrusion e Perform troubleshooting procedures for Problem Code 6 Service Manual page 23 17 e Temporary failure erase the problem code and re test the unit Code 11 Motor driver circuit Can be caused by a shift motor short water intrusion e Perform troubleshooting procedures for Problem Code 11 Service Manual page 23 21 NOTE If you install a new ECM on a unit with a failed shift motor you may damage the new ECM Initialization Procedure It is extremely important to perform the steps in the initialization procedure on Service Manual page 23 6 as quickly as possible Mechanical Troubleshooting Low Oil Pressure Low oil pressure is often caused by a stuck pressure relief valve in the oil pump assembly Look for the following symptoms of a stuck pressure relief valve e Grinding noise e Ratchetin
4. g noise Freewheeling no compression braking Must perform a pressure check e Bench check the oil pressure If the oil pressure is OK on the bench you need to perform a pressure check when the unit is exhibiting the problem NOTE If the pressure relief valve was sticking it does not necessarily mean the Hondamatic is dam aged Most Hondamatics received through Warranty are not damaged Replace the oil pump replace the Hondamatic only if it is truly damaged see Hondamatic Malfunction below Hondamatic Malfunction The following are common causes of mechanical Hondamatic failure Swash plate lock e This is a temporary failure and can be fixed by following the unlocking procedure on Service Manual page 23 15 Note that problem codes 5 and 6 may be triggered as a result of a swash plate lock condition e Improper initialization or no initialization after replacing the angle sensor can also cause this condition Bearing Damage Will cause the Hondamatic to bind When riding the unit it may feel like the brakes are applied NOTE If there is a mechanical failure of the Hondamatic transmission you must replace the unit as an assembly The transmission is not repairable Z HONDA gt THE WRENCH 2004 American Honda Motor Co Inc All Rights Reserved Published by AHM Motorcycle Service Communications 1919 Torrance Blvd Torrance CA 90501 All suggestions become the property of American Honda Motor Co I
5. he Service Man ual section Problems Not Detected by ECM page 23 23 Electrical Pin Fit A crucial first step before you begin electrical troubleshooting is to check all electrical connections for loose contact In order to check for proper connector pin fit order the following Special Tool Terminal Inspection Feeler Set P N 07XMJ 001000A H C 7198518 Tool Technique When you re checking pin fit with the above tool a slight drag on the feeler means the pin fit is correct Retrieve Problem Codes Start your electrical troubleshooting by retrieving problem codes Most calls to TechLine are made before the techni cian has checked for codes You should always check for codes first e Problem Code Retrieval Procedure see Service Manual page 23 4 e For all possible problem codes refer to the problem code list on Service Manual page 23 8 To erase problem codes see Service Manual page 23 5 Common Problem Code Decoder Use the following problem code explanations to assist your diagnosis Code 2 Speed Sensor Circuit e Often causes an inaccurate speedometer e Usually due to water intrusion of the speed sensor e Perform troubleshooting procedures for Problem Code 2 Service Manual page 23 10 Code 3 Gear Position Circuit e Perform troubleshooting procedures for Problem Code 3 Service Manual page 23 11 e To properly check the gear position switch there are a total of 16 resistance checks To see the proc
6. nc sending a suggestion gives American Honda permission to publish it without further consideration Editor Bill Willis MSN 10633 0405 TRX500FA FGA Troubleshooting Questionnaire Complete this questionnaire with the customer before you begin troubleshooting Hondamatic transmissions In which gear position did the problem occur in If ESP what mode In which mode did the problem occur in ESP or AUTO D1 D2 LOW or DRIVE What type of conditions where you were riding Mud water trails asphalt pulling a trailer climbing hills other Was anything being carried on the racks Have any accessories or modifications been made to the ATV Winch Large wheels tires Lift kit Have any repairs been performed recently What was the vehicle speed when the problem occurred Does the speedometer work correctly Is it accurate Did you try to turn the ignition key OFF and then ON again to see if the problem cleared How long before the failure repeated RO Technician s Name nate Z HONDA
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