Recall Radar

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

Recall 05-583 · June 24, 2005 · Polaris

What to doFree repair. Contact your Polaris ATV dealer to schedule an appointment for ECM replacement. Polaris has notified registered affected consumers directly about this recall.

Read the official CPSC notice

Recall at a glance

Recall number
05-583 (CPSC)
Recall date
June 24, 2005
Brand
Polaris
Category
Sports, bikes and outdoor
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
Hazard
Fire and burn hazard
Hazard type
Fire and burn
Units
About 61,020 (This recall was first announced in May 2005)
Made in
United States
Last updated by CPSC
December 18, 2024

What was recalled

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

Is my product affected?

Compare your product with the details below, including model numbers where listed.

  • 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 · About 61,020 (This recall was first announced in May 2005) units

Photos from the recall notice

Recalled 2004.5 Sportsman ATV
Recalled 2004.5 Sportsman ATV
Recalled 2005 Sportsman ATV
Recalled 2005 Sportsman ATV
Recalled 2005 Scrambler ATV
Recalled 2005 Scrambler ATV

Where it was sold

Companies named in the notice: Polaris dealers sold these ATVs nationwide, from August 2004 through February 2005, for between $3,799 and $7,699.; Polaris Industries Inc., of Medina , Minn..

Injuries or incidents reported

Polaris has received 68 reports of the ECM overheating. No injuries have been reported.

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

Recall history and context

Polaris appears in 124 CPSC recalls on record. See all Polaris recalls.

Since 2019 CPSC has recorded 451 recalls in the sports, bikes and outdoor category, 74 recalls of them in the past 12 months.

Frequently asked questions

What was recalled?

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 (About 61,020 (This recall was first announced in May 2005) units). Only select model year Polaris ATVs are part of this recall.

Why was it recalled?

CPSC lists the reason as: Fire and burn hazard.

What should I do if I own one?

Free repair. Contact your Polaris ATV dealer to schedule an appointment for ECM replacement. Polaris has notified registered affected consumers directly about this recall.

More recalls from Polaris

Similar recalls in sports, bikes and outdoor

  • HatsanUSA Recalls Blitz Air Rifles
    October 15, 2026 · HatsanUSA · Sports, bikes and outdoor

    This recall involves all units of the Hatsan Blitz and Blitz 777 pellet shooting air rifles sold from February 2020 through March 2026. Both the Blitz and Blitz 777…

  • Pacearth Direct Recalls PACEARTH Swing Seats
    October 8, 2026 · Pacearth Direct · Sports, bikes and outdoor

    This recall involves PACEARTH U-type swing seats. The swing seats were sold in various colors including green, blue, pink, red and turquoise. The chain is coated in…

  • Decathlon America Recalls Van Rysel GRVL AF Bicycles
    October 8, 2026 · Decathlon · Sports, bikes and outdoor

    This recall involves adult multi-terrain gravel bicycles Van Rysel GRVL AF Sword Brown CN FR (model number 8911304), Van Rysel GRVL AF Apex Beige CN FR (model number…

  • Walmart Recalls Over 4.4 Million Expert Grill Brushes
    October 1, 2026 · Walmart · Sports, bikes and outdoor

    This recall involves certain Walmart Expert Grill metal wire bristle grill brushes. The brushes have black plastic or stainless-steel handles. Some brushes come with…

  • Golden Resale Recalls Portable Camping Showers
    October 1, 2026 · Golden Resale · Sports, bikes and outdoor

    This recall involves Portable Camping Showers with a bucket and immersion heater. The shower system consists of a black rechargeable electric shower pump, a black shower…

  • 5Color Recalls Children’s Bicycle Helmet and Pads Sets
    September 24, 2026 · 5Color · Sports, bikes and outdoor

    This recall involves 5Color-branded bicycle helmet and pads sets. The sets consist of a pink helmet, knee and elbow pads. Only the size small helmets are included in…

Source: U.S. Consumer Product Safety Commission recall data, shown as published and last updated by CPSC on December 18, 2024. Details can change; the official notice is the authority. If your product may be recalled, stop and read the notice before deciding what to do. Terms and disclaimer.