June 4, 2008
Alert #08-580

The following product safety recall was voluntarily conducted by the firm in cooperation with the CPSC. Consumers should stop using recalled products immediately unless otherwise instructed. It is illegal to resell or attempt to resell a recalled consumer product.

Name of Product: Polaris All-Terrain Vehicles (ATVs)

Units: About 700 (About 95,000 have been reannounced in Feb. 2008)

Manufacturer: Polaris Industries Inc., of Medina, Minn.

Hazard: The ATVs can have defective Electronic Control Modules (ECM) that overheat, posing a fire and burn hazard to riders.

Incidents/Injuries: Since the recall expansion announced in February 2008, Polaris has received four more reports of ECMs melting and two reports of smoke or fire contained to the ECM. No injuries have been reported.

Description: This recall involves the Polaris ATVs with model year 2004 and model numbers listed below that have been serviced for electrical problems and received a defective EMC during service work. The ATVs were sold under market names Scrambler 500 and Sportsman 400, 500, or 6 x 6. The model number is printed on a decal attached to the front side of the radiator (Sportsman) or the top of the front cab cover (Scrambler 500).

Model YearModelMarket Name
2004 A04BG50AA Scrambler 500 4x4
2004 A04BG50FA Scrambler 500
2004 A04CH42AQ Sportsman 400
2004 A04CH42AR Sportsman 400
2004 A04CH42AS Sportsman 400
2004 A04CH42AT Sportsman 400
2004 A04CH42AV Sportsman 400
2004 A04CH50AO Sportsman 500
2004 A04CH50AQ Sportsman 500
2004 A04CH50AR Sportsman 500
2004 A04CH50AS Sportsman 500
2004 A04CH50AT Sportsman 500
2004 A04CH50AV Sportsman 500
2004 A04CH50AW Sportsman 500
2004 A04CH50AX Sportsman 500
2004 A04CL50AA Sportsman 6x6

Sold at: Polaris dealers nationwide from July 2004 through January 2008 for between $3,800 and $7,900.

Manufactured in: United States

Remedy: Consumers should disconnect the negative (black) battery cable from the battery when the ATV is not in use. Consumers should contact their local Polaris dealer to schedule a free repair. Registered owners received direct mail notification of this recall.

Consumer Contact: For additional information, contact Polaris toll-free at (888) 704-5290 between 8 a.m. and 5 p.m. CT Monday through Friday, or visit the firm's Web site at www.polarisindustries.com

Picture of Recalled ATVPicture of Recalled ATV