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Louie
Louie, Technician
Category: Motorcycle
Satisfied Customers: 11428
Experience:  25+ yrs. experience
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I have a 2004 honda rancher 400 at that will not shift, i

Customer Question

i have a 2004 honda rancher 400 at that will not shift, i reiniatlized the system and the shift motor does not seem to spin, can anyone help?
Submitted: 8 months ago.
Category: Motorcycle
Expert:  Louie replied 8 months ago.

Hi Nick and welcome to JustAnswer,

Thank you for the question and your patience. Should you still need assistance for information purposes only...

Initially, proposed preliminary tries (if have not been done)

  1. • check/ replace the shift control motor fuse;
  2. • determine battery voltage when:
  • ignition OFF - 12.7V is good;
  • and then when ON - 12.5 is good;
  • when starting the engine - 11.0V is good;
  • engine at idle - 12.9V is good;
  • when attempting to rev the engine - 14.5V is good.
Customer: replied 8 months ago.
hi louie, Voltage is fine, i have no power to the shift motor whatsoever, the fuse is good, there is no power on the green and orange wires coming out the cdi box, should there be a 5volts to that or no? please help thanks again!
Expert:  Louie replied 8 months ago.

Appreciate the post back.

Does the neutral indicator lights up correctly/as expected?

Still, let's try going back to basics; were you able to run diagnostic?

Customer: replied 8 months ago.
how do you do that? and yes the neutral indicator is lit up, when the key is turned on, esp and -- symbol show up,it flashes 6 times, i just replaced the angle sensor because that is what code six calls for i believe, how do you run dignostics?
Expert:  Louie replied 8 months ago.

Bear with me and let's go back to "...green and orange wires..." To my recollection, the green wire on a Honda almost always is tied to ground hence no voltage would be as expected. On the other hand, the orange wire to the shift motor would only be present when attempting to shift. This motor would also go CW and CCW thus the orange wire wire would not always be a +V. With this in mind, there would be another wire to the shift motor but not green.

Please re-check.

And do you have an electronic copy of the Service Manual?

Apologies for delays; Internet is sluggish if at all available while mobile.

Customer: replied 8 months ago.
i do not have a service manual for this machine no, and there are ony two wires not three
Expert:  Louie replied 8 months ago.

Could the other wire to the shift motor perhaps be a green/red?

Customer: replied 8 months ago.
green with a red tracer
Expert:  Louie replied 8 months ago.

The pure green wire is tied to ground.

These orange and green/red wires provide voltage to the shift motor BUT changes polarity; i.e. to be able to turn the motor clockwise and counter-clockwise to perform the shifting.

When testing for voltage, test between these 2 wires, orange and green/red not to ground nor the green wire and only when attempting to shift.

Customer: replied 8 months ago.
louie there is only two wires to the shift motor, an orange a green with a red tracer
Expert:  Louie replied 8 months ago.

I understand Nick. Please re-confirm that there is no measurable voltage between these 2 wires (orange & green/red) when attempting to shift.

  • If no voltage, then check red/yellow wire to the ECM for presence of IGN +12V
  • If voltage present when attempting to shift, disconnect the shift motor connector and measure the resistance of the shift motor.
Customer: replied 8 months ago.
What should the resistance of the motor be?
Expert:  Louie replied 8 months ago.

Very low Ω with the value varying depending on the condition of the carbon brushes and commutator segments. Equally important is that this measured resistance should not change (much) as the motor is manually turned.

Customer: replied 8 months ago.
hey louie, just getting back to this project its been a long week, when i put the machine in tot he relearn mode for the angle sensor i have voltage at the shift motor but nothing if i just put it in gear and try to shift, i believe its some kind of safety device this way you cant shift it if the angle sensor is out of adjustment, furthermore the motor only has resistance of 2.5ohms i didnt take it off to manually spin the motor
Expert:  Louie replied 8 months ago.

Appreciate the post back Nick.

"...some kind of safety device this way you cant shift it if the angle sensor is out of adjustment..."; agree BUT for it not to shift, then there should be NO "...voltage at the shift motor..."

Even if the angle sensor is off adjustment, the mere presence of voltage should cause the motor to partially spin and therefore shift.

What is the value of the "...voltage at the shift motor..."?

And is this voltage ONLY present when attempting to shift?