Polaris RZR Off-Road Vehicle Recall Issued Over Fuel Leak, Fire Risk

Roughly 53,000 recreational off-highway vehicles (ROVs) have been recalled by Polaris, following reports that suggest the fuel lines may leak, posing a risk of fires and burns for riders. 

A Polaris RZR recall was announced by the U.S. Consumer Product Safety Commission (CPSC) on October 6, following at least 29 consumer complaints that the vehicle’s fuel tank vent line was misrouted, causing the line to pinch and leak fuel. At least two of the reports involved vehicles catching fire, with at least one rider suffering a burn injury.

The recall includes 2015 Polaris RZR ROV’s with model numbers RZR 900, RZR S 900, RZR 4 900, RZR 900 XC, RZR XP 1000, RZR XP4 1000, and the RZR XP 1000 Mudder. The recall only involves specific VIN ranges included in the 2015 models.

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All of the recalled models have a decal of the model name “RZR” on the front right or left fender. Owners can locate the ROV’s vehicle identification number on the driver’s side rear frame tube, behind the PVT cover and verify if the vehicle is included in the recall by visiting the recall announcement linked above.

Polaris has received four reports of the fuel lines leaking from the RZR 900 models, in which two resulted in the vehicles catching on fire. Only one of the incidents resulting in fire led to a burn injury to the rider. In addition, Polaris received 25 reports of fuel leaks involving the RZR 1000 model.

The vehicles can easily catch fire if there is a fuel leak anywhere near the motor housing or frame. If a fuel leak is present and any contacting component of the vehicle becomes hot from use, the leaking fuel line may catch on fire, posing serious burn hazards.

The recalled Polaris vehicles were manufactured in China and the United States under Polaris Industries Inc., of Medina, Minnesota where they were distributed for to Polaris dealers nationwide from July 2014 through August 2015 for $12,800 to $18,300 for the RZR 900 models and between $20,300 to $23,500 for the RZR 1000 models.

Customers are being asked to stop riding the recalled vehicles immediately and contact Polaris toll free at 888-704-5290 or visit them online at www.polaris .com and navigate to the Product Safety Recalls tab for information on how to schedule a free repair at their local dealer. The CPSC announced Polaris has started contacting each registered owner directly by phone and mail.

3 Comments

  • JoeJune 24, 2019 at 12:31 am

    2015 RZR 900 gas line leaking all over vehicles , need yamaha to fix?

  • AlexissFebruary 4, 2016 at 4:58 pm

    Our 2015 4 seater burned to the ground with only 250+/- miles on it and basically because I have insurance that covered the machine polaris's engineers (by looking at a picture only) say "Engineering's review did not identify a defect with the vehicle. Polaris is unable to verify if the cargo was properly fastened and it may have contacted the fuel pump assembly.The claim has been covered by insur[Show More]Our 2015 4 seater burned to the ground with only 250+/- miles on it and basically because I have insurance that covered the machine polaris's engineers (by looking at a picture only) say "Engineering's review did not identify a defect with the vehicle. Polaris is unable to verify if the cargo was properly fastened and it may have contacted the fuel pump assembly.The claim has been covered by insurance and as such, no additional goodwill coverage will be provided from Polaris." Such a joke! It was a machine that was recalled in October but was already burnt up in June!

  • donaldDecember 15, 2015 at 5:24 pm

    My 2013 Polaris 800 caught fire my 18 son and 12 were in driveway my son was burned I called Polaris took to dealer 3 weeks later no disposition they told me they are looking into it I explained I have a 500 acre farm I use it daily they told me not their problem they don't own them dealer responsible

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