I have a 2007 Foreman 500 ES with 15 hours on it. I've been getting a random code 2 for the past week and a half. I first got it last week out riding and brought it to the honda dealer where I bought it and they were supposedly able to get it to act up right away. They replaced the TP sensor wire involved in the recall checked some wiring and the angle sensor and said it didn't act up anymore and that it was good. Well I brought it home thursday, and while I was at my rider safety coarse today it started acting up again!!

Well I was smart and bought a used HONDA service manual while I was at the dealership last week(I am a ford mechanic so I understand and have a fairly high mechanical ability). What I am wondering is what is the ECM seeing in the code 2(up/down switch) that it's not liking. I see in the schematics, that the harness for the ES runs through the TP sensor as well. Have you guys been seeing any burned out resistors on the TP sensors setting a code, or any sticking ES switchs? I plan to take the fenders off tomorrow and ohm out the TP sensor and check for a bad spot. I also want to check all the wiring harness connectors that the dealer supposedly checked. I just hate driving 3 hours both ways to drop off/pick up the machine(twice a week) and not have it fixed.

Also, it seems that the code only sets(and when it does my ES is disabled) when I come to a STOP. If I am moving it is fine until I come to a complete stop(wheel speed zero). It still drives after the code sets and begins to flash, but the ES just won't shift until I turn the ign off and reset the ECM.

Any help would be great!! This is starting to bug me, it's a new machine that isn't even to it's first service hours and already i'm regretting buying the ES!! We've had a 99' fourtrax at home for 9 years and we've NEVER had a problem....

 

Scratch that..... When I brought my wheeler in, I ASSUMED that the dealer ran the pinpoint test for a code 2 under ESP(which involved inspection of the ECM and switch wiring harnesses). Well I went out today and pulled the rack and fenders off and did the diag myself. After pulling the ECM harness(looked good), I went to the 14P Green connector mounted to the side of the ECM. Upon pulling it apart, water poured out and a few of the pins even had green oxidation on them. Well I ran into work and grabbed some DeOxit and brake cleaner. Came home and cleaned the harness(and checked the rest since I had the fenders off), and installed dielectric grease. Reassembled and cleared the code. Test drove in the parking lot of my apartment complex, and so far it's good.

If the dealer had infact performed the test, they should have found the water(because I've only had it back since thursday, and have not ridden or washed it since.....with the acception of the safety coarse in a dry field).

Hope this fixes the problem, it was starting to bug me!!

 

0 blinks: No problem
1 blink: ECU
2 blinks: ES Shift up / down shift system or shift release / related wire harness or ECU
3 blinks: Angle sensor
4 blinks: Gear position switch system
5 blinks: ECU motor driver
6 blinks: ECU fail-safe relay circuit
7 blinks: ECU Voltage convert circuit
8 blinks: Angle Sensor control motor
9 blinks: Angle Sensor short or related wire
10 blinks: Ignition pulse generator
11 blinks: Speed sensor
12 blinks: Gear position switch

i hope this helps and if the warranty does not cover it just give em hell because it just shuold not do that

cody

 

Thanx, but I already know what the codes are. I bought a Honda service manual while I had it in at the dealer last week(I am a mechanic for a local Ford Dealership). All the pinpoint tests/wiring diagrams/assembly/disassembly instructions. I ran the code 2 pinpoint test for the ES switch assembly(Up/Down) and found the water in the harness. If the dealer had ran the pinpoint test for a code 2, they should have found that water. I'm thinking the randomness of the code setting is more than likely the water in the harness, so we'll see what happens when I take it out next weekend....

 

oh im sorry thot u just wanted the codes