Note: This recall has been reannounced.
-
Image of recalled 2004.5 Sportsman -
Image of recalled 2005 Sportsman -
Image of recalled 2005 Scrambler
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.
About 61,020 (This recall was first announced in May 2005)
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
Recall Details
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) | A05MH68(CA) | 4XAMH68C*5A 353612 - 353618 |
| 4XAMH68C*5P 461037, 461039 | ||
| 2005 Sportsman 6X6 | A05CL50(AA) | 4XACL50A*54 549671 - 558303, 796545 - 799527 |
| 2005 SCRAMBLER 500 | A05BG50(AA) | 4XABG50A*52 523011 - 523889, 527617 - 528865, 529468 |
| 4XABG50A*54 554662 - 558475, 796577 - 799530 | ||
| 2005 Trail Boss 330 | A05CA32(AA) | 4XACA32A*5B 410751 - 413970 |
| 4XACA32A*52 532233 - 541659, 751061 - 757439 | ||
| 4XACA32A*54 550569 - 558765 | ||
| A05CA32(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 |
Free repair. Contact your Polaris ATV dealer to schedule an appointment for ECM replacement. Polaris has notified registered affected consumers directly about this recall.
Polaris has received 68 reports of the ECM overheating. No injuries have been reported.
Polaris Industries Inc., of Medina , Minn.
Note: Individual Commissioners may have statements related to this topic. Please visit www.cpsc.gov/commissioners to search for statements related to this or other topics.
If you are experiencing issues with a recall remedy or believe a company is being non-responsive to your remedy request, please use this form and explain the situation to CPSC.
Related Recalls
The recalled children’s and youth helmets violate the mandatory safety standard for bicycle helmets. Particularly, the helmets do not comply with the positional stability and coverage requirements. The helmets can fail to protect the user in the event of a crash, posing a risk of injury or death due to head injury.
The stoves can explode or catch fire, posing a burn and fire hazard to consumers.
The coaster brakes can fail to engage, resulting in the rider losing control, posing a crash hazard.
The pump’s canister can forcefully eject from the base when pressurized, posing a risk of serious injury from impact to the user or bystander.
The left front wheel can detach during use, posing a fall hazard.
The bike’s seat post assembly can break during use, posing fall and injury hazards to the user.
The U.S. Consumer Product Safety Commission (CPSC) is charged with protecting the public from unreasonable risk of injury associated with the use of thousands of types of consumer products. Deaths, injuries, and property damage from consumer product-related incidents cost the nation more than $1 trillion annually. Since the CPSC was established more than 50 years ago, it has worked to ensure the safety of consumer products, which has contributed to a decline in injuries associated with these products.
Federal law prohibits any person from selling products subject to a Commission ordered recall or a voluntary recall undertaken in consultation with the CPSC.
For lifesaving information:
- Visit CPSC.gov.
- Sign up to receive our email alerts.
- Follow us on Facebook, Instagram, X, BlueSky, Threads, LinkedIn and Truth Social.
- Report a dangerous product or product-related injury on www.SaferProducts.gov.
- Call CPSC’s Hotline at 800-638-2772 (TTY 800-638-8270).
- Contact a media specialist.
