CPSC, Polaris Industries Announce Expanded Recall of Select Model Year 2004.5 and 2005 ATVs
U.S. Consumer Product Safety Commission recall (2005-06-24). Hazards: fire, burn. About 61,020 units in the US.
| Agency | U.S. Consumer Product Safety Commission |
|---|---|
| Recall number | 05583 |
| Published | 2005-06-24 |
| Last updated | 2024-12-18 |
| Product category | All Terrain Vehicles (ATVs) |
| Products | 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 |
| Firm named in the title | Polaris Industries |
| Firms | Polaris Industries Inc., of Medina , Minn. (manufacturer) |
| Manufactured in | United States |
| Units (US) | 61,020 |
| Hazard classes | fire, burn |
| Remedy classes | repair, replace |
| Sold | Polaris dealers sold these ATVs nationwide, from August 2004 through February 2005, for between $3,799 and $7,699. |
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 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
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.
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.
Incidents and injuries
Polaris has received 68 reports of the ECM overheating. No injuries have been reported.
Machine access
This record, with every extracted field, the source record (contact text and images withheld) and provenance: GET https://api.data.aroqon.com/v1/product-recalls/cpsc-05583. Look up a model number or UPC with /v1/product-recalls/lookup?code=…. About the dataset · free and paid keys.
Source: U.S. Consumer Product Safety Commission recall notice (US Government work). Not affiliated with or endorsed by CPSC. Structured by Data Foundry (product-recall-structuring@2); last changed 2026-09-28. Always confirm with the agency notice.