CPSC, Polaris Industries Announce Expanded Recall of Select Model Year 2004.5 and 2005 ATVs

June 24, 2005
Alert #05-583
 

NOTE: This recall, which was an expansion of a previous recall, has been expanded.

CPSC, Polaris Industries Announce Expanded Recall of Select Model Year 2004.5 and 2005 ATVs

The following product safety recall was conducted voluntarily 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 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.

Units: About 61,020

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

Hazard: 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.

Incidents/Injuries: Polaris has received 68 reports of the ECM overheating. No injuries have been reported.

Description: 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 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

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

Manufactured: United States

Remedy: Free repair. 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

Picture of Recalled 2004.5 Sportsman ATV

2004.5 Sportsman

Picture of Recalled 2005 Sportsman ATV

2005 Sportsman

Picture of Recalled 2005 Scrambler ATV

2005 Scrambler