M505 will no longer sync

Hello,
Syncing problems - but different.
I am trying to sync an old m505 to a new HP desktop.
- Palm m505, OS 4.1
- new HP desktop: Windows 7 Pro, 32-bit.
The m505 has worked fine for years on a previous XP computer (now dead from hard drive failure). Syncing via serial cable.
On the new PC I installed and reinstalled both Palm Desktop 4.1.4 and then 6.2,. along with palmhotsyncsetup. But still no luck - the sync cannot establish a connection. I've done a soft reset twice and now a hard reset.
I even bought a serial to usb adapter thinking maybe the usb cradle/charger was faulty, but that didn't work either.
Now the strange part... I have another m505 (given to me as a backup - I wasn't sure if it would even charge up as it sat in drawer for past few years...). I tried to sync with cradle/charger and it connected! So how can that be? As far as I know the only difference between the 2 hand-helds is that my current device's OS is 4.1 and the back up device was never upgraded, so OS is still 4.0. I don't recall now what the upgrade details where from 4.0 to 4.1.
So now I uninstalled Palm Desktop 6.2 software again. Reinstalled 4.0 from disk. Upgraded to Palm Desktop 4.1.4 and then synced to the 2nd device. So far it seems to be working.  BUT, the 2nd device won't hold a charge so is not reliable. I left it charge overnight and it still will only stay on for a few seconds and turns off.
Has anyone heard of this issue? Why would one device (same model) be able to establish sync connection and the other not? When it was working fine in Windows XP just days ago?
Any insight/advice appreciated
Stumped,
Brent
Post relates to: Palm m505

Check the HotSync settings on the device that refuses to sync - perhaps it's set to some other method than cable!
Compare both devices.  Pull down the HotSync menu from the top left corner and go line by line.
WyreNut
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