Hello all,

Well at 2500 mi (of hills and rocks and Appalacia) the Rubicon has rebelled. Last week at Windrock i lost a front left bearing. It is replaced and replacement knuckles for both sides are on the way. Problem dealt with. Coming in off the trail it has started a new (and i fear more serious problem).
When I shift to "D" It engages and runs fine. When i shift to "L" it does not show a gear position but instead i get a "--" which does not blink. It engages the ESP low gear (super low) and continues to run (not in selected esp mode). Strangely now in ESP the old super low position 1 will show on the indicator but the engaged gear seems to be a higher ratio than the old "1". It will shift in ESP from 1-2-3-4-5 as usual. Prior to this existing problem there were 3 or 4 very recent instances when the shifter woul not go into the "L" position at all but then this would clear up and work. I have inspected the external shifting linkage and all seems OK. I am taking off the fenders etc at this point for further inspection. I have read the service manual on this and wonder if the gear position selector switch / harness could cause this but really at this point i need some help. Thanks to all for taking the time to read and hopefully respond.

Beagles

 

Pretty Please :-)

 

Sounds more like a dirty or loose connection somewhere

just my guess


Did you replace both front wheel bearings?

Better replace the Rear ones too

they go about every 4grand :-x

Also if you have a lift kit your going to be throwing new front wheel bearings in every 2000 or so miles :-X

 

Thanks 650cc, At Windrock i replaced the bearing in the mud and rain. The Rubicon was tortured the nect 2 days at Spring Jam. On the way in was when the shifting hassle began. As information now that it is home I replaced both front knuckles with upper ball joints and the left rear axle pipe assy. This should end the bearing hassle for awhile. This weekend I will start ripping all the plastic off so i can test the ECM and connections. If some kind sole can point me in the right direction on this I would appreciate it but as always i will post the final resolution here. Thanks again 650cc

Beagles

 

Remove the ECM by pulling the rear cargo compartment out by backing out the (2) mounting screws in the side. The ECM is mounted to the top of the cargo compartment.

It's a lot easier than pulling the plastic.... Twich

 

Thanks Twitch. Actually the plastic is already srripped (completely). I did it for inspection/maintenance and the likelyhood that whatever i had to repair
would be a battle to work around the plastic. Still no resolve on the problem. I am stumped.

Again for those who wish to weigh in:

When I shift to "D" It engages and runs fine. When i shift to "L" it does not show a gear position but instead i get a "--" which does not blink. It engages the ESP low gear (super low) and continues to run (not in selected esp mode). Strangely now in ESP the old super low position 1 will show on the indicator but the engaged gear seems to be a higher ratio than the old "1". It will shift in ESP from 1-2-3-4-5 as usual. Prior to this existing problem there were 3 or 4 very recent instances when the shifter woul not go into the "L" position at all but then this would clear up and work


I have at this point 4 guesses.

1. Gear position sensor
2. Angle Sensor
3. Sub Transmission selector fork
4. Loose connector somewhere in the hondamatic system.

Again thanks to all. I will update as i learn.


Beagles

 

It's very easy to check 1 & 2 and if you need details write back, but don't hold your breath because it sounds a lot more like an ECM failure than a sensor problem.

 

1. Gear position sensor....... Much more learned about this machine. Will post when time allows. Thanks to all who joined in.


beagles

 

my freind has a 450 es he had sort of the same problem and it was the sensor[img]i/expressions/face-icon-small-smile.gif[/img]

 

Well at 2500 mi (of hills and rocks and Appalacia) the Rubicon has rebelled. Last week at Windrock i lost a front left bearing. It is replaced and replacement knuckles for both sides are on the way. Problem dealt with. Coming in off the trail it has started a new (and i fear more serious problem).
When I shift to "D" It engages and runs fine. When i shift to "L" it does not show a gear position but instead i get a "--" which does not blink. It engages the ESP low gear (super low) and continues to run (not in selected esp mode). Strangely now in ESP the old super low position 1 will show on the indicator but the engaged gear seems to be a higher ratio than the old "1". It will shift in ESP from 1-2-3-4-5 as usual. Prior to this existing problem there were 3 or 4 very recent instances when the shifter woul not go into the "L" position at all but then this would clear up and work. I have inspected the external shifting linkage and all seems OK. I am taking off the fenders etc at this point for further inspection. I have read the service manual on this and wonder if the gear position selector switch / harness could cause this but really at this point i need some help. Thanks to all for taking the time to read and hopefully respond



Well here's how it went down.

Pulled the ECM and plugged it into a friends Rubicon. The ECM would not reset or clear code 6. Ran the flowchart on the ECM-Angle Sensor and C/O
the angle sensor with my friends angle sensor. Code 6 still will not reset. Ordered new ECM and angle sensor from Service Honda and installed on arrival.
code 6 is gone but still no L position. Ran flowchart on gear position sensor and SURE ENOUGH no continuity on the white wire to the Senosr-Ground circuit. Jumpered the White wire to ground and EUREKA The L appears. Drank several beers to celebrate and ordered new G P Sensor, A Warn 4-2-4
Select, All new body plastic (HIDY Honda gives a good deal), 72 Stanless 1/4' marine fasteners to replace those cheesy Honda black fasteners, New Front brake shoes. New left & right rear axle housings with bearings factory installed. Installed all mentioned and adjusted valves / carb and SET THE PLUG GAP!!! The Rubicon is now yellow with new Honda decals and all new black plastic as well. The stainless marine fasteners are very nice against the
black. The 424 select turned it into a Go-Kart. The tune up turned it into a ROCKET. This machine is scary. In D-1 at 5mph I gunned it and unexpectedly the front wheels came off the ground (just a bit) on flat pasture ground. The biggest performace gain was seen after setting the plug gap (on a new IR
NGK plug) Now it starts with no choke used and would likely rope start. I mounted the 424 select on the handle bars by welding the bracket to the bar near the headlight. (Slick). 2500 ODO miles and this Rubicon will return to Coal Creek this weekend. Mrs beagles is happy to get her Yamaha back and i must say its been a pleasure to ride in the interim. Thanks to Service Honda, Thanks to Hidy Honda, and again thanks to all the folks here. I will monitor this thread to help on Rubicon questions whre i can.

beagles