Went to the dealer today as they had My 05 400 sportsman ready to go,After I got there thay told Me they would not cover the recalled module under warranty after they had already told Me they would.
$260.00 bucks to get the POS out the door and I am not real happy right now.
here`s a pic of the inside of the old module and the harness connector.All the white/grayish looking stuff is from moisture and condensation and also the blue looking crap in the harness connector.I feel that if the harness had been properly installed with any kind of silicone paste on the gasket that no moisture should have been able to get into this unit.FYI the only water this ATV has ever seen was about 2 to 3 inches of rain on top of the ice at Hell Creek on Fort Peck.
Also here is the link to the previous thread on this matter.
http://forums.atvconnection.com/pola...ms-recall.html

 

Is that your first factory one?
My first factory one was Black in color on the 2006 Sp 450........Caper.........

 

Nope this is the third one.
The original was replace on the recall.

 

So now i`m doing a little expirement.
I plugged the harness into the connector and set the module in the sink with a couple of coffee cups to supprt it,I filled the sink to just below the level of where water will run into the module,I`m trying to find out of the moisture came in through the connector or if it got in through the o ring gasket on the back cover.
I will let it set in the sink for a couple of hours and check for moisture or water and if it is still dry then I will install the o ring and back cover and submerse it again for a couple of hours then remove the back cover and see if there is moisture in it then.
If not then I would have to say that it was full of water when it was assembled at the plant wherever that might have been.

 

After leaving the ECU partially submerged in water with the harness connected it leaked water around the harness connection.
Now I think I had better remove the harness connector from My new ECU and see how well it is sealed before this happens again.
I am also going to beadblast the corrosion from the harness connector and clean the corossion from the suppose to be bad unit and try it out and see if it will still work.

 

If I had a ECM I would silicon the hell out of it, and turn it into a submarine.

 

YUP!!!
That new one is coming off and it is going to get the sealing of it`s life.
If the old one will still work after getting it cleaned up I think I will leave it on and pack the new one for a spare.
who knows,maby the old one will get claimed as being the new one before the 90 day warranty runs out then I`ll have two new ones.LOL

 

What were your three issues ?
I am on my third one also with my 2006 Sp 450........Caper.........

 

I don't understand why more riders don't buy the Polaris carb version . If I had a 06 and was on my 3rd ECU it would be sold . Even my carb yes has a PDM but I don't read of many faulty units like I do with the ECU'S . I trust my bike nearly 4000 miles problem free ( ok one Bendix) but dam I never worry . Once it starts I know its getting me home never a sensor or a black ( silver ) box to worry about . I guess only time will tell as I'm going for 20,000 miles in 6 years . Is there any riders on this form who have 20,000 miles problem free on a EFI machine please speak up . In the mean time I'll keep you posted on my quest to 20 thousand 4.5 years to go

 

the main issue was that the ECU or whatever You want to call it was replaced under the recall and was only eight months old it then filled up with water by driving on the ice with about 2 to 3 inches if water on the ice and the water splashing off of the tires filled it with water about 3 months the terminals in the harness and the ECU corroded and then I could not get anything to power up.
The second issue is that these are suppose to be water/moisture proof and there should not have been any water got into the unit in the first place and they would not cover it under warranty.