Pdm was just as bad imo as the ecm... Replaced a bunch of those to over the years mainly from non charging issues.

 

Well called dealer today and they tried a different ecm and it didn't work. They told me they have good battery and they have removed all accessory, checked all relays, grounds and whatever else they think to have as an issue. They are having trouble tracing the wires cause the voltage is there then it dissapeared. They have suggested a wiring harness now which is $478 plus labor and it might not fix it lol. Should the wiring harness be covered if it's the issue and should it not be covered maybe ecm has damaged it some where. I'm wondering why they can't find the problem it's an atv not a rocket ship. What's your thoughts?

 

My thoughts are that you're up against a rock and a hard place if they can't find the problem. You or the dealer would have to prove that the Chinese ecm was definitely responsible for a wire harness problem before Polaris would even consider covering it also. No different than any other manufacturer would do. Pretty pricy on the harness and labor as you can get one yourself for $261 and install it yourself along with the warrantied ecm they supplied. This is one way you might consider. Most dealers or independent shops don't have the time or wont take the time because of the amount of labor tracing each and every wire. That's why a harness is a cheaper way to go.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Just thought I would weigh in here. I had a similar problem with my 06 Sportsman 500. Same symptoms you are describing. The dealer replaced the ecm under the recall for me. Still had a intermittent problem. I replaced the ignition switch myself and in the process I found the pin receptacles in the wiring harness plug had some that were loose and backing out of the connector. Cleaned the connection and restaked the female receiver and it has worked like a champ ever since.

 

Thx guys...will azk the dealer if he checked for pins loose......if they replace the harness and it doesn't fix the issue am I too pay for the part and labour????from the dealer.

 

Yes you'd have to pay as they explained that to you,plus their labor. The dealer couldn't return the harness same as you couldn't on electrical parts unless Polaris would possibly allow them minus any restocking fees.No dealer no matter how good they may be are going to eat parts that they've paid for. But pins pulling back out of connectors as mentioned can be one source of the problem that you might pass on to them while they still have your machine to check for.

 

I'm in canada so the part is 260 US. ...with conversion and taxes and duty and shipping would be $400 cdn plus labour. Dealer is 480 plus labour....so about $100 difference. Make dealer do it then he is on the hook to finish the job......Definitely will ask if they could check pins.....I'm starting to hate this.....

 

Have they tried to start it by using the pull rope ? Possible the trigger coil gap is too wide , there's been posts about this problem on several forums . If it starts with the rope they will need to tighten the gap on the trigger coil .

 

Old polaris tech what ya think of last comment about trigger coil gap ? Considering you have read all my posts. Thx scott

 

Your original post was for it dying and instrument panel not lighting up. Plus erratic operation which normally were some of the symptoms of the ecm failing. Pulse coil gap being too wide is basically not being able to start it with the electric starter,but able to start with the recoil was an ignition problem,but when this happened there normally wasn't the erratic display problems or other symptoms like you've had.Here's the original post on this.no spark to plug when using electric starter - Page 3 - ATVConnection.com ATV Enthusiast Community But you might have them check while it's in the shop.