I have a 2006 Sportsman 500 EFI with a strange electrical problem. When I turn the key to run, everything lights up on the display and the fuel pump cycles. When I turn the key to start, the starter does not try to kick over and the display goes blank. I have to turn the key off and then back on and the display is normal again and the fuel pump cycles.

It will start and run fine with the pull starter, just not with the electric start. It is as if the electric system shut off when I turn the key to start.

In my manual it says there is a Battery Ptotection Output circuit in the Power Distribution Module that will shut down if there is an overload or short. Does anyone know what could cause problems with this circuit or any other causes of this problem?

 

start at the battery, check to make sure it is a good battery and fully charged, a multi meter will confirm that it has over 12 vols while stopped, clean all the connections at battery ,then do the elenoid, take the battery cable off and check the nuts under them for corrosion and tightness then follow wires up the frame to headligt podif starter doesnt even turn sounds like bad battery , bad connections or bad selenoid or starter, should be able to jump across selenoid , if it starts its the selenoid

 

Sounds like a bad battery to me.

 

I agree on checking battery connections. Easy first step to check your battery is to pull start it then check the voltage. If that is good then check voltage while trying to start it with the key. If it is a huge drop when the key is turned on then you most likely have a bad battery or connection. Any battery store can run a load test on it(free) to confirm if the battery is bad. How long does it sit between use and do you use a trickle charger? They will greatly increase battery life and you can get them for under $10 at harbor freight. I keep all of mine on one when not in use and have never had any battery issues.

 

yep start by checking the battery voltage in the dianostic mode to see what it reads. it should be at least 12.5 volts or better.

 

Thanks for the replies. It is not the battery. It has good voltage. The voltage does not drop when I turn the key to start. All of the electronics go dead when I turn it to start. I'm going to swap out the solenoid from my wife's Polaris to see if that is the problem. I thought it might be a bad ignition switch, but I switched her good one to mine and it still does the same thing.
I'm pretty sure it is going to be the PDM. It has solid state circuit breakers instead of fuses. I think those are tripping when the key goes to the start position.