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Electrical problems on a 2007 Sportsman 500 pdm

Problems with an electrical issue. Check everything I could think of on the bike. Once in a while it would start with the switch. It would start by pulling the rope. Decided to use a hair dryer and heat up the pdm. Got it hot, hit the switch, and it started right up. Did this several times and started every time. Let it get cold and it wouldn't start. Sent off for a new pdm. Let you know for sure as soon as the new pdm arrives.
awa
 

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Tracked the problem to about 90% sure it was the pdm. Found a place on ebay that repaired them(a lot less then a new one) and ship them back. That was the problem. Works like new. Sure found how to take the machine apart.
awa
 

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I know this post has been beaten about and well covered. This may help the next person. It is obviously a common issue with the electrical shutting off and on or completely shutting down. I had it on my 2007 500x2. I scoured the internet and spent hours tracing wires for issues. Everything appeared OK. I even pulled apart the PDM and saw no obvious issue. Finally what I discovered was that when the key was TURNED ON the power from the PDM (pin M on SSCB2 yellow wire) to the ignition switch was turning off and on and sometimes always off. Therefore the problem. I was getting full time 12 volts to pin H on SSCB1 red wire into the PDM. From what I have learned (I think) is that there is some sort of electronic link in the PDM that acts like a fuse which fails or partially fails. My fix : And saved the big bucks. I ran a wire from the battery + to a 10amp fuse and then to an off/on switch then to the yellow wire going to the ignition. I left the yellow wire from switch to PDM intact. If the machine doesnt turn on normally I turn the switch on and everything powers up. Everything works and I have had no issues doing this.
 

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Hickeyhill, My 07 500X2 EFI shutoff on me yesterday. All it does now is make a humming noise which seems to be coming from in or under the gas tank when I turn the key. The gauge was acting crazy also. I'm going to try your method if charging the battery doesn't help. Also welcome to the forum!
 

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Update

To Corbett1973

Even though my "cheap" fix worked I bit the bullet and purchased a new PCM with fingers crossed and it was the issue. Your issue sounds a bit different than mine did. I had nothing when turning the key on although occasionally it would turn on and I would hear the electronic fuel pump fire up and then all would shut down. Good luck in the search for the problem. It can be frustrating
 

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Modulemaster

Tracked the problem to about 90% sure it was the pdm. Found a place on ebay that repaired them(a lot less then a new one) and ship them back. That was the problem. Works like new. Sure found how to take the machine apart.
awa
The ebay place was it modulemaster by any chance? I think the PDM went out on my sportsman.
 
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