There was a recall on some serial numberd units in 2005 and polaris replaced and/or tested alot of these units/modules. I think some were sent back to polaris to get "reflashed" as they called it. Now caper got the new module which is alot bigger, has more wires, and is of a differnt shape and color. I have seen this replacement and hope it works. I love our 500, but there is no way I can fix an ECM/module problem out on the trails 100 miles from civilization and to me these things crash way to often.

 

Here is the reason the NEW one from Polaris is called the "KIT" Part#2203348..From dealer Invoice.....
It comes with the 1. Power Distribution Module(PDM).........................Part #4011803
2. Small tube of NyoGel Dielectric Grease................Part #2871329
3.Harness-Jumper,Sure Power...............................Part #2410921
4.Instructions.................................... ................Part #9921137

this comes all in one box!!!

Application:
2006 and Earlier Polaris Sportsman 450/500,Sportsman 6x6,500 Scrambler..

Note with this kit the wires from the quad are not plugged directly into the PDM(like the old part) they use the Harness to plug in first(to PCM) then the wires from the quad plug into each tail from that jumper........

So it is just a way of plugging in the same connectors to a totally different device!!!!!Without cutting!!!

Any more questions just ask...........Caper............

 

Also I should post this for your info:...In the Service Manual ............
The ECM or PDM......integrates three electronic features found on the Polaris ATV.These are:................

1.alternator rectifier/regulator,

2.temperature controller,..(Note controls fan motor)Hot Light also if it keeps rising!!!

3.Solid state circuit breaker outputs.......(this was my trouble)
The first output is (BAT_PROT) routed to the key switch is active all the time.....power for lamps,pod,front hub coils,

The second output is used for the accessories.......

Here is my problem explained.......The BAT_PROT output is protected from overloads and short circuits. If a overload or short happens that output shuts off!!!!!My lights when turned on would shut the quad off...............If I turn light switch off and restart quad ......Run good until I turn the high/low switch on!!!!!!!!!Hope this info helps someone...........And YES STENDORI.......THIS DOES ALOT!!!!!..Caper

 

see the man that know, mr. caper lol. esp. w/ that nice service manual.

 

Years ago on the snowmobiles If you could not keep headlights in them(from blowing the bulbs) you knew it was a voltage regulator...........
Now with all this"STUFF" the whole quad is under the watch-full eye of the ECM..OR PDM..........If there is something weird going on with your electronics..........My first guess would be this "BOX"............And Yes Stendori........If I didn't have the Manual.........I would never have known how much this did control.............Caper..........

 

yea like i said somewhere that the old days were so much easier and i miss them.

 

Hi,
I am new to the forum but need to tell this. I have a Polaris 2005 Sportsman 400. I got it in Feb of 2005. Since May of 2006 my 4 wheeler has been apart in my brothers garage because of several factors. The first thing I noticed going wrong was I was overheating and I could not for the life of me keep the battery charged. I bought a new battery thinking the original one was bad, didn't work. I still could not keep the battery charged. After a wash one day I noticed my plastic where my leg rests while sitting was all melted. I checked this because my leg was getting very very hot and actually burning. A few days later while charging this brand new battery, my 4 wheeler started smoking and was on fire. After we put the fire out my ECM and harness that the ECM goes into were both melted and fried. I called our local dealer and was CHARGED $300 + for a new harness and another $122 for a new ECM....now my question is this. I have not had my 4 wheeler for a year this month because of this. When I first called my dealer why was I not told about any recall on anything? I just went yesterday and got yet another ECM ($107.00 this time) and still was not told of this recall. The reason I found out about this recall is because the part did not look like what I have and what I first originally bought right after this happened, and so I questioned this and was told "Polaris must have had a problem with the original one in my 4 wheeler so they modified it" thats when I started thinking maybe there was a recall and checked the internet to find it. Needless to say, Its been a year now (money is tight and had to fit parts for my 4 wheeler in when I could) my 4 wheeler is still apart in my brothers garage and I am madder then hell that I was not told about this recall to begin with. I now have the new modified ECM and a new harness and My brother is once again going to try to get my 4 wheeler going. But you can beat your bottom dollar some heads are going to be swinging. Oh and just for the record, I have not checked my vin number yet, but will later today. Sorry this is so long but I needed to vent somewhere. Thanks for listening.

Darlene[img]i/expressions/face-icon-small-mad.gif[/img]

 

Check out this site about ECM recalls...... my serial number is not listed, but still had to replace it out of warranty!
I hear the faulty units were made in China, big surprise !

http://www.consumeraffairs.com/recal..._expanded.html

Polaris should do the right thing and replace ALL faulty units at no cost.
Good luck....

 

Well here it goes. I checked my vin and low and behold my vin is indeed in the recall list. My brother called Street Track and Trail and was told they didn't know about any recall (hard to believe) and that they need to research this and get back to him. That was about 3 hours ago, I am still waiting for a phone call to find out just what they are going to do about this and if I am going to get my money back for all the parts I have already bought (2 ECM's and a new harness from it catching on fire). If not I am thinking on contacting a lawyer to fight this for me. Has anyone dealt with Polaris themselves with this problem? I'd like to know what Polaris is doing about it if they are contacted. Any input would be greatly appreciated.

Darlene[img]i/expressions/face-icon-small-happy.gif[/img]

 

No big surprise that the dealer didn't now about the recall, I don't think Polaris and their dealers communicate very well.
I have an '04.5 400 Sportsman that had an over rich problem that the factory knew about and the dealer did not, drove it that way for a year and it almost killed me when it quit on a hill. Found out about the problem on a forum, told the dealer about it and they called Polaris...... surprise! They did rejet it at no cost....wow.
As for my bad ECM, I'm still waiting for my serial number to be added to the recall.
As far as calling Polaris direct, good luck.... cause I didn't have any. I was told that Polaris leaves costumer service to the dealers... hmmmm.
It didn't leave me with a good feeling, that's 4 sure.
Don't get me wrong, I still like the machine....