Polaris ATV Recall

[Dave]

Name of product: Polaris 2004.5 Sportsman 500, 2005 Sportsman 400, Sportsman 500, Sportsman 600, Sportsman 700, and 2005 Scrambler 500

Units: About 14,882

Hazard: Some 2004.5 and 2005 Model Year Sportsman and 2005 Model Year Scrambler 500 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. Affected units can be verified by comparing the last six digits of the Vehicle Identification Number (VIN) to the serial number range in bold type below. NOTE: Not all 2004.5 and 2005 vehicles are affected. Please review the affected unit table below.

Incidents/Injuries: Polaris has received 26 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 VIN, or serial number is permanently stamped into the left frame rail behind the left front wheel of all Polaris ATVs.

Model(s) Affected Model Number(s) Serial Number Range-(last six numbers of VIN)

2004.5 SPORTSMAN 500 A04CH50AR AXACH50A*4 407617 - 407876

2005 SPORTSMAN 400 A05MH42AB 4XAMH42A*5A 354270 - 354759, 360481 - 360630

4XAMH42A*5B 411353 - 412822

4XAMH42A*5A 353730 - 354269, 360631 - 360780

4XAMH42A*5B 411832 - 411832, 413068 - 413137

2005 SPORTSMAN 500 A05MH50AB

A05MH50AC

A05MH50AG

A05MH50AH 4XAMH50A*5A 350562 - 351321, 355431 - 355580, 359016 - 359730, 362935 - 362979

4XAMH50A*5B 407877 - 408216, 411873 - 411912, 415275 - 416014, 417015 - 417299

4XAMH50A*5A 355581 - 355835, 358431 - 358715, 359831 - 360290

4XAMH50A*5B 411913 - 412207, 415350 - 415419, 416015 - 416279, 417315 - 417614, 418310

4XAMH50A*5A 350342 - 351590, 355280 - 355430, 358716 - 359790

4XAMH50A*5B 408217 - 408556, 411833 - 411872, 415200 - 415274, 416280 - 416564, 417615 - 418114

4XAMH50A*5A 350782 - 351051, 355130 - 355279, 359231 - 359630, 362765 - 362854

4XAMH50A*5B 412208 - 412332, 415420 - 415754, 416715 - 417014, 418510 - 418704

2005 SPORTSMAN 600 A05MH59AK 4XAMH59A*5A 349790 - 350341

2005 SPORTSMAN 700 A05MH68AK

A05MH68AN

A05MH68AP 4XAMH68A*5A 349720 - 349789, 351776 - 352060, 353253 - 353487, 356181 - 356390

4XAMH68A*5A 360901 - 361285, 362707 - 362764, 363575 - 363646

4XAMH68A*5A 349719, 351591 - 351775, 353488 - 353729, 355836 - 356180

4XAMH68A*5A 360781 - 360900, 361286 - 361545, 362582 - 362706

4XAMH68A*5A 362597 - 362609

2005 SCRAMBLER 500 A05BG50AA 4XABG50A*52 523011 - 523889, 527617 - 528602

*=Check Digit. This could be either a letter or a number

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.

[MNmikew]

Thanks for the news Dave. And I just picked up an '05 Sportsman 500 last week. Dang!

[Mike89]

very interesting, I was having trouble with my 05 500 and they never said a word about a recall. They just replaced the module.

[MNmikew]

Mike, what were the symptoms your were seeing? I'm taking my '05 Sportsman on it's maiden voyage this weekend.

[Mike89]

the instrument panel messed up. The speed needle would flash and the battery light would flash. The battery was fully charged. then the rest of the cluster started flashing!! Then it went blank completely!! But the best part was the machine kept on going!! Now with the new part all is fine. 20 minutes to replace it. I really enjoy ours, you will too!! Mike

[peerchking]

I picked up my new 500 three weeks ago. I brought it home unloaded it,went down the drive and back about 1/4 mile total. Overheated! I took it right back and they replaced some sencer. It hasn't missed a beat since

[MNmikew]

Thanks for the info guys! I checked my VIN when I got home and I'm not on the list, though I will keep an eye on it this weekend. I've had mine around the yard a few times and it seemed OK cooling wise. Sure is a different beast than my 01 Scrambler 500. I'll report any troubles I have with it this weekend back here.

Mike

[Dave]

MNmike, NO, do not report troubles here! The "other brand guys" will jump all over ya... Just kiddin'.

[Macgyver55]

Who do you mean Dave?

[Dave]

See, mention the words, trouble and Polaris, and look who pops in... Remember, Mac, I've got the ban button...

[umdr6]

My buddy has the 2004.5 Sportsman 500. As soon as I read this, I had to call him. He has owned his ATV for 8 months. Has been in the shop 6-7 times for it overheating. The ATV would overheat after 2-3 miles of riding. No one could figure out the problem. The dealership tried to blame it on him, saying he has been riding it too hard.

-------They are fourwheelers, you should not have to baby them like your Porsche or Lexus. They are meant to handle rough trails.

His wheeler has overheated on everytrip that we have taken, and because of it, we have not successfuly completed an ATV trip. I am going to pring this thread and bring it to him and the mechanic that has been working on it. I am glad that it is Polaris's problem, not his.

Thank you for whoever started this thread!

~umdr6

[Dave]

umdr6, hold on there bud. The recall is for the ECM overheating, not the engine. Although, maybe with a malfunctioning ECM the engine could overheat I'm not sure exactly. Getting anything fixed that's under recall is the first step though. Good Luck!

[umdr6]

Dave,

This is true. I found that out when I went in there yesterday. The first thing the mechanic said was "We already replaced the ECM!" He found many many mor eproblems with that Sportsman though.

I am glad I ride a Yamaha!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[Dave]

Polaris Industries, Inc. has added approximately 45,000 additional units to a recall it originally announced May 3.

The May recall included approximately 14,882 Polaris ATVs after the company received 26 reports of Electronic Control Modules (ECM) overheating. Units included in the original recall were the 2004.5 Sportsman 500 and 2005 Sportsman 400, Sportsman 500, Sportsman 600, Sportsman 700 and 2005 Scrambler 500.

On June 24, Polaris added select 2005 Sportsman 6x6, Trail Boss and Magnum 330 ATVs for a total of 61,020 units recalled due to a possibly defective ECM. Polaris says it now has received 68 reports of the ECM overheating. No injuries have been reported.

Manufactured in the United States, the first batch of recalled units were sold nationwide from August 2004 through February 2005 for between $5,999 and $7,299. The second batch of ATVs was sold nationwide from August 2004 through February 2005 for between $3,799 and $7,699. Polaris says it has notified registered affected consumers directly about the recall and asked them to schedule an appointment for ECM replacement.

[MNmikew]

I talked to my dealer yesterday about getting mine replaced. They said there is now a test device that is used to determine if you have a bad ECM. Takes 5 mins but you have to bring it in. They also said the backorder of the ECMs if you need one could take up to a MONTH!

They also said to make sure you UNHOOK YOUR BATTERY. Even if you dont run it. My dealer knew of two machines that started on fire, yikes. Bad enough to lose the wheeler let alone everything in the garage.

[Dave]

Thanks for the update, MNmikew!