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 Affected | Model Number(s) | Serial Number Range |
|---|---|---|
2004.5 SPORTSMAN 500 | A04CH50( AO)(AR)(AS) | 4XACH50A*4A 347719 - 348073 |
| 4XACH50A*4B 407412 - 407876 | ||
2005 SPORTSMAN 400 | A05MH42 (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 500 | A05MH50 (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 600 | A05MH59 (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) | A05M H68(CA) | 4XAMH68C*5A 353612 - 353618 |
| 4XAMH68C*5P 461037, 461039 | ||
2005 Sportsman 6X6 | A05C L50(AA) | 4XACL50A*54 549671 - 558303, 796545 - 799527 |
2005 SCRAMBLER 500 | A05B G50(AA) | 4XABG50A*52 523011 - 523889, 527617 - 528865, 529468 |
| 4XABG50A*54 554662 - 558475, 796577 - 799530 | ||
2005 Trail Boss 330 | A05C A32(AA) | 4XACA32A*5B 410751 - 413970 |
| 4XACA32A*52 532233 - 541659, 751061 - 757439 | ||
| 4XACA32A*54 550569 - 558765 | ||
A05CA3 2(AB) | 4XACA32A*54 551800 - 553997 | |
2005 Magnum 330 2X4 | A05CB32( AA) | 4XACB32A*52 527107 - 529313, 537673 - 542424, 752671 - 753030 |
| 4XACB32A*5B 405797 - 405846, 408757 - 409346, 413971 - 414270, 675331 - 679450 | ||
2005 Magnum 330 4X4 | A05CD32( 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).