June 25, 2005
Polaris is expanding an earlier recall, adding the following models: Polaris Model Year 2004.5 Sportsman 500, Model Year 2005 Sportsman 400, Sportsman 500, Sportsman 600, Sportsman 700, Sportsman 6x6, Scrambler 500, Trail Boss and Magnum 330 ATVs.

Some 2004.5 and 2005 Model Year Sportsman, Scrambler 500 ATVs, Trail Boss and Magnum 330 ATVs were assembled with possibly defective Electronic Control Modules (ECM) which may fail and overheat. If this were to occur, excessive heat could cause a fire, possibly resulting in serious injury or death.

Polaris has received 68 reports of the ECM overheating. No injuries have been reported.

Only select model year Polaris ATVs are part of this recall. The Sportsman ATV model and serial number identification decal is located on the front side of the front radiator covering. The Scrambler 500 ATV model and serial number identification decal is located on top of the front cab cover.

The Vehicle Identification Number (VIN), or serial number is also permanently stamped into the left frame rail behind the left front wheel of all Polaris ATVs. Affected units can be verified by comparing the last six digits of the VIN to the serial number range in bold typed below. NOTE: Not all 2004.5 and 2005 model year vehicles are affected. Please review the affected unit table below.

Models AffectedModel Number(s)Serial Number Range
2004.5 SPORTSMAN 500A04CH50(AO)(AR)(AS)4XACH50A*4A 347719 - 348073
4XACH50A*4B 407412 - 407876
2005 SPORTSMAN 400A05MH42(AB)(AG)(AH)4XAMH42A*5A 343374 - 343413, 353730 - 355129, 360331 - 360780, 373808 - 374327,379785 - 380385, 600801 - 602060, 609261 - 610515
4XAMH42A*5B 411353 - 415199, 418895 - 427514, 430095 - 430634, 675596 - 676621, 679861 - 680700
2005 SPORTSMAN 500A05MH50(AB)(AC)(AG)(AH)(AL)4XAMH50A*5A 343334 - 343373, 350342 - 351590, 355130 - 355835, 358431 - 360330,362765 - 365588, 373208 - 373807, 378452 - 380569, 600301 - 600800, 605111 - 606260, 609111 - 609665, 612059 - 612811
4XAMH50A*5B 404297 - 404796, 407877 - 408556, 411833 - 412332, 415200 - 431444, 675381 - 681370
2005 SPORTSMAN 600A05MH59(AK)(AN)4XAMH59A*5A 343286 - 343333, 349790 - 350341, 365589 - 366670, 372908 - 377872
2005 SPORTSMAN 700 A05MH68(AK)(AN)(AP)4XAMH68A*5A 342736 - 343285, 349130 - 356390, 360781 - 377252, 604711 - 605110
(non -military application)A05MH68(CA)4XAMH68C*5A 353612 - 353618
4XAMH68C*5P 461037, 461039
2005 Sportsman 6X6A05CL50(AA)4XACL50A*54 549671 - 558303, 796545 - 799527
2005 SCRAMBLER 500A05BG50(AA)4XABG50A*52 523011 - 523889, 527617 - 528865, 529468
4XABG50A*54 554662 - 558475, 796577 - 799530
2005 Trail Boss 330A05CA32(AA)4XACA32A*5B 410751 - 413970
4XACA32A*52 532233 - 541659, 751061 - 757439
4XACA32A*54 550569 - 558765
A05CA32(AB)4XACA32A*54 551800 - 553997
2005 Magnum 330 2X4A05CB32(AA)4XACB32A*52 527107 - 529313, 537673 - 542424, 752671 - 753030
4XACB32A*5B 405797 - 405846, 408757 - 409346, 413971 - 414270, 675331 - 679450
2005 Magnum 330 4X4A05CD32(AA)(AB)(AC)4XACD32A*52 521885 - 522981, 528132 - 529815, 532671 - 541374
4XACD32A*5B 405847 - 405896, 409347 - 410750, 414271 - 414534, 431445 - 431756, 675001 - 679051

Polaris dealers sold these ATVs nationwide from August 2004 through February 2005 for between $3,799 and $7,699.

Consumers should contact your Polaris ATV dealer to schedule an appointment for ECM replacement. Polaris has notified registered affected consumers directly about this recall.

Consumer Contact: Call Polaris at (800) 765-2747 between 8 a.m. and 12 midnight ET everyday, or log on to the company’s Web site at www.polarisindustries.com

The recall is being conducted in cooperation with the U.S. Consumer Product Safety Commission (CPSC).