Polaris recalls

For affected vehicles there is concern that a crack may develop in the EMC (Electromagnetic Compatibility) filter(s) within the vehicle's charging system potentially allowing water to contact high voltage charging harness components.

Fix: Inspection of the EMC filter(s) and harness(s) for signs of damage and replace where required including installation of a cover assembly.

• RANGER XP KINETIC: 35 vehicles · built 21 Jun 2023 to 13 Feb 2024
• RANGER XP KINETIC: 9 vehicles · built 17 Jan 2024 to 6 May 2024
• RANGER XP KINETIC: 78 vehicles · built 11 Jul 2023 to 25 Jul 2024

On certain vehicles the high voltage cables on the Motor Controller Unit (MCU) can become loose.

Fix: Inspection of motor controller unit and its components for signs of electrical arc cable misalignment cross-threaded fasteners and general damage/wear.

• RANGER XP KINETIC: 3 vehicles · built 12 Oct 2023 to 27 Nov 2023
• RANGER XP KINETIC: 26 vehicles · built 11 Jul 2023 to 31 Jan 2024

On affected vehicles the passenger seat belt mount for the buckle may not be properly welded. This could result in the anchor point separating from the frame.

Fix: Affected vehicles will be checked and if required a new seat belt crossbar will be fitted.

1 vehicle · built 13 Dec 2023 to 13 Dec 2023

Affected 2023-2024 model year Polaris Sportsman 850 XP 1000 and XP 1000 S ATVs may experience a fuel leak at the fuel pump flange outlet.

Fix: Replacement of the fuel pump and a PFA cover and jumper harness will be installed.

6 vehicles · built 18 Jan 2024 to 18 May 2024

On affected vehicles the red battery terminal cover can be damaged if the seat is not correctly mounted. A damaged or an improperly seated battery terminal cover may result in an exposed positive (+) battery post.

Fix: Verify the condition and if necessary replace the red terminal cover.

• RZR XP 1000: 5 vehicles · built 27 Apr 2023 to 9 Feb 2024
• RZR XP 1000: 6 vehicles · built 27 Apr 2023 to 9 Feb 2024

On affected vehicles a crack can develop at the exhaust header resulting in an exhaust leak near combustible material posing a fire hazard.

Fix: A revised exhaust head pipe will be fitted to affected vehicles.

• EGIMOTORS SPORTSMAN XP1000S: 3 vehicles · built 1 Jan 2021 to 31 Dec 2023
• EGIMOTORS SCRAMBLER XP1000S: 2 vehicles · built 1 Jan 2021 to 31 Dec 2023

Affected vehicles may have an unfused electrical harness which may overheat posing a fire hazard and risk of serious injury.

Fix: Check and fit a fused wiring harness.

• RANGER EV: 131 vehicles
• RANGER EV: 16 vehicles · built 1 Jan 2019 to 31 Dec 2022

On certain vehicles activating the brake and throttle pedals simultaneously may result in a loss of throttle response. If the brake is then released the vehicle may move and the throttle may still be deactivated posing a crash hazard and risk of serious injury.

Fix: Conduct an update to the vehicle control system to prevent these symptoms. This includes a calibration update to the Main Bike Board (MBB) controller.

• RANGER XP KINETIC: 1 vehicle · built 1 Jan 2023 to 29 Feb 2024
• RANGER XP KINETIC: 2 vehicles · built 1 Jan 2023 to 29 Feb 2024

Under certain operating conditions some models may have an increased risk of primary (drive) clutch failure.

Fix: To resolve this concern install a new primary clutch assembly fuel line bracket and complete an ECU calibration update for affected units.

2 vehicles · built 1 Jan 2021 to 31 Dec 2021

Certain vehicles may experience a steering rack failure during operation.

Fix: Do not use the vehicle and replace the steering rack assembly.

142 vehicles · built 1 Jan 2021 to 29 Feb 2024

A fuel leak at the fuel pump outlet connector on the fuel tank may occur.

Fix: Inspect and depending on findings and model replace the fuel pump assembly or fuel tank.

• RANGER XP 1000: 17 vehicles · built 25 Feb 2021 to 7 Jul 2022
• CREW 1000: 17 vehicles · built 25 Feb 2021 to 7 Jul 2022
• RANGER XP 1000 CREW: 17 vehicles · built 25 Feb 2021 to 7 Jul 2022
• RZR PRO XP: 17 vehicles · built 25 Feb 2021 to 7 Jul 2022

A wiring harness may have been improperly assembled by the supplier and wires may contact the brake line and/or vehicle frame.

Fix: Inspect and then secure the stator wires.

• SPORTSMAN 570: 488 vehicles · built 8 Jul 2020 to 22 Sep 2022
• SPORTSMAN 450: 488 vehicles · built 8 Jul 2020 to 22 Sep 2022

Fuel may ignite by electrostatic discharge outside the fuel tank whilst refuelling.

Fix: Do not drive and replace the fuel hose clamps and fit a fuel spill diversion plate where appropriate.

• SCRAMBLER 1000S: 128 vehicles · built 18 Dec 2019 to 21 Jul 2022
• SPORTSMAN 1000S: 128 vehicles · built 18 Dec 2019 to 21 Jul 2022

With degraded fuel and especially after extended storage some snowmobiles may pose a risk of fire due to electrostatic discharge (ESD) inside the fuel tank.

Fix: If a rider needs to start their snowmobile they must make sure the fuel tank is full and if it is not then they need to add fresh gasoline to fill the tank. To resolve this concern Polaris has developed a procedure to update the fuel pump assembly.

• TRAIL PERFORMANCE: 2 vehicles · built 24 May 2016 to 24 Aug 2016
• MATRYX: 2 vehicles · built 24 May 2016 to 24 Aug 2016
• AXYS: 2 vehicles · built 24 May 2016 to 24 Aug 2016

The throttle speed control stop can break if the throttle speed control bracket is contacted with excessive force.

Fix: Do not drive and follow procedure to replace the speed control bracket on all affected vehicles.

188 vehicles · built 31 Aug 2010 to 27 Oct 2020

Certain models may have a raised edge on the turbocharger at the oil supply line sealing surface which could result in an oil leak posing a fire hazard.

Fix: Inspect the turbocharger and where necessary replace the turbocharger unit.�

2 vehicles · built 4 May 2021 to 24 May 2021

The front lower control arm bolts could separate under operation.

Fix: Replace the front lower control arm bolts and washers with a higher-grade version.

471 vehicles · built 17 May 2017 to 20 Dec 2018

Vehicles could have been assembled with incorrect front suspension spring retainers.

Fix: Inspect and replace the front suspension spring retainers if necessary.

2 vehicles · built 10 Oct 2019 to 11 Oct 2019

Throttle pedals that may be slow to release or may stick in the depressed position.

Fix: An updated throttle pedal needs to be installed in all affected vehicles.

• RANGER 1000: 27 vehicles · built 14 Apr 2020 to 24 Sep 2020
• RANGER XP 1000: 27 vehicles · built 14 Apr 2020 to 24 Sep 2020

Possible damage to the vehicle�s fuel line in the event of drive belt breaks or fails during operation.

Fix: Fit a protective shield to prevent fuel pipe damage.

9 vehicles · built 12 May 2020 to 24 Sep 2020

A fuel pump flange assembly that when exposed to certain chemicals may degrade over time.

Fix: Install a model specific fuel pump cover to shield the pump flange from potential contamination.

26 vehicles · built 13 Jan 2016 to 3 Jan 2018

Some 2020-2021 RZR models may have an increased risk of primary (drive) clutch failure

Fix: Inspect the and replace the primary clutch if necessary.

• RZR PRO XP / PRO XP 4: 32 vehicles · built 2 Aug 2019 to 18 Mar 2020
• RZR XP TURBO / XP 4 TURBO: 32 vehicles · built 2 Aug 2019 to 18 Mar 2020
• RZR TURBO S / TURBO S 4: 32 vehicles · built 2 Aug 2019 to 18 Mar 2020

Certain 4-point and 6-point seat belt harnesses may have been manufactured with missing belt stitching.

Fix: Check and replace the belt assembly if required.

• RZR PRO XP / PRO XP 4: 24 vehicles · built 14 Jan 2015 to 18 Mar 2020
• RZR XP / XP 4 TURBO S: 24 vehicles · built 14 Jan 2015 to 18 Mar 2020
• RZR XP / XP 4 1000: 24 vehicles · built 14 Jan 2015 to 18 Mar 2020
• RZR XP / XP 4 TURBO: 24 vehicles · built 14 Jan 2015 to 18 Mar 2020

Certain 4-point and 6-point seat belt harnesses may have been manufactured with missing belt stitching.

Fix: Check and replace the belt assembly if required.

34 vehicles · built 14 Jan 2015 to 18 Mar 2020

The throttle lever stop might have been damaged during shipping

Fix: Check for damage on the neck of the throttle lever. If damage is found the throttle lever shall be replaced.

9 vehicles · built 27 Oct 2017 to 1 Sep 2018

Some 2020 RANGER XP 1000 and RANGER Diesel vehicles may have been produced with a drive clutch stationary sheave that was manufactured incorrectly.

Fix: Inspect and measure drive clutch components. Replace the EBS sleeve if required.

• RANGER XP 1000: 57 vehicles · built 18 Nov 2019 to 20 Feb 2020
• RANGER DIESEL (INTL): 57 vehicles · built 18 Nov 2019 to 20 Feb 2020

Engine Control Unit (ECU) calibration may prevent the throttle plates from returning to idle position after an engine stalling.

Fix: Updating ECU calibrations of the affected vehicles.

• GENERAL XP 1000: 24 vehicles · built 7 Aug 2018 to 3 Feb 2020
• GENERAL 1000: 24 vehicles · built 7 Aug 2018 to 3 Feb 2020
• RANGER XP 1000: 24 vehicles · built 7 Aug 2018 to 3 Feb 2020

Some 2019-2020 RANGER XP 1000 models were built with the fuel line routed incorrectly

Fix: Inspect the fuel line routing and route correctly if needed

3 vehicles · built 31 Oct 2019 to 21 Nov 2019

Fuel line may be damaged in the event of a drive belt failure

Fix: Updated clutch outlet duct mount fitted to protect the fuel line in the event of drive belt failure

192 vehicles · built 28 Feb 2019 to 10 Sep 2019

Excess current may lead to terminal damage

Fix: Reposition the main chassis fuse

25 vehicles · built 15 May 2014 to 25 Apr 2016

Fuel line may be damaged in the event of a drive belt failure

Fix: Updated clutch outlet duct mount fitted to protect the fuel line in the event of drive belt failure

333 vehicles · built 7 Sep 2017 to 10 Sep 2019

Incorrect electrical wiring to the accelerator pedal position sensor.

Fix: Modify the wiring harness.

115 vehicles · built 23 Jun 2014 to 14 Jan 2019

The backup camera could fail internally and cause the fuse for the rear lights to blow.

Fix: Inspect the camera version and replace if necessary.

21 vehicles · built 15 May 2014 to 8 Oct 2015

An improperly routed parking brake cable can contact the electrical harness and cause premature wear.

Fix: Inspect the wiring harness for premature wear and repair as necessary as well as reroute the parking brake cable.

• RANGER DIESEL CREW: 1,326 vehicles · built 13 Oct 2015 to 25 Jun 2018
• RANGER DIESEL HD: 1,326 vehicles · built 13 Oct 2015 to 25 Jun 2018

Throttle lever damaged during shipping.

Fix: On affected vehicles replace throttle lever.

• PHOENIX 200: 60 vehicles · built 19 Jul 2013 to 25 Jan 2017
• PHOENIX 200: 60 vehicles

Fuel pump flange that when exposed to chemicals may degrade and leak causing fire risk.

Fix: Fit a fuel pump cover to shield the pump flange from potential contamination.

• ACE 500: 7 vehicles · built 11 Aug 2016 to 28 Feb 2018
• ACE 570: 7 vehicles · built 11 Aug 2016 to 28 Feb 2018
• ACE 900: 7 vehicles · built 11 Aug 2016 to 28 Feb 2018

Heat shield may not adequately shield exhaust gasses in the event of an exhaust silencer crack. This could cause nearby components to melt and pose a fire hazard.

Fix: Replace heat sheild on affected vehicles.

• RZR XP 1000: 135 vehicles · built 22 Jul 2013 to 19 Feb 2018
• XP4 1000: 135 vehicles · built 22 Jul 2013 to 19 Feb 2018

Fuel pump flange that when exposed to chemicals may degrade and leak causing fire risk.

Fix: Fit a fuel pump cover to shield the pump flange from potential contamination.

• RZR XP TURBO: 75 vehicles · built 14 May 2015 to 14 Feb 2018
• RZR 570: 75 vehicles · built 14 May 2015 to 14 Feb 2018
• RZR S 1000: 75 vehicles · built 14 May 2015 to 14 Feb 2018

Driver-side and passenger-side seatbase frames may have been improperly manufactured Driver-side seatbase frames may also contain a seat slider defect.

Fix: Frames on affected vehicles will be checked and if necessary replaced.

23 vehicles · built 22 Apr 2014 to 26 Feb 2018

Indian Motorcycle has determined that some motorcycles equipped with halogen headlights may have been assembled using a non-compliant headlight not matching destination market requirements. Certain International models may be equipped with an SAE (North America spec) headlight which is considered non-compliant per ECE standards. The E4 and SAE headlights have different photometric and marking requirements which must be inspected and if necessary replaced with the correct headlight.These headlights have the potential to dazzle other road users if the light is not dipped to the correct side for the market operated in.

Fix: Headlamp assembly to be inspected on affected models and where necessary the headlamp will be replaced.

• SPRINGFIELD: 6 vehicles · built 4 Apr 2017 to 16 Aug 2017
• CHIEF: 6 vehicles · built 4 Apr 2017 to 16 Aug 2017
• CHIEFTAIN: 6 vehicles · built 4 Apr 2017 to 16 Aug 2017

it has been determined that the upper steering shafts on 2016-2017 GENERAL Vehicles may exhibit movement along the length of the power steering spline. In extreme circumstances this movement may ultimately result in separation of the shaft from the spline which may lead to the loss of steering. This movement may ultimately result in separation of the shaft from the spline which may lead to the loss of steering

Fix: Polaris is releasing this Safety Bulletin for dealers to install revised steering shaft hardware with a higher torque and clamp-load specification.

13 vehicles · built 1 Dec 2015 to 2 Aug 2017

Some vehicles may have been manufactured with an exhaust head pipe that does not meet Polaris quality standards. As a result the exhaust temperatures may degrade the exhaust head pipe to the point where a hole or crack may form. This could pose a potential fire and/or burn hazard.

Fix: To resolve this concern the exhaust head pipe will be replaced.

57 vehicles · built 12 Dec 2013 to 15 Dec 2014

In the event of a stuck throttle cable the ECU will illuminate the check engine light but will not limit engine RPM or vehicle speed.

Fix: A calibration update that enables the ECU to place the engine into safe mode in the event of a stuck throttle cable. Polaris is contacting its customers and sending a recall letter to each registered owner.

50 vehicles · built 11 Oct 2013 to 26 May 2017

Some vehicles may have been manufactured with fuel tanks that do not meet Polaris quality standards. As a result the fuel tank may crack resulting in a fuel leak. A fuel leak in the presence of an ignition source may present a fire hazard.

Fix: A new updated fuel tank will be fitted to affected vehicles to replace the original tank.

174 vehicles · built 1 Oct 2014 to 24 Feb 2017

Some vehicles may have been manufactured with wiring harnesses that may short to ground with no circuit protection.

Fix: A harness kit will be fitted to add an in-line fuse for the un-switched power circuit together with chafing protection for the starter cable. The overall condition of the harness will also be inspected to ensure the ground circuits are properly connected.

123 vehicles · built 15 Sep 2014 to 21 Mar 2016

Polaris Industries Inc. (Polaris) have issued a STOP ride and STOP sale notice on a small number of machines. These machines were manufactured with a fuel tank vent line end location in the headlight pod which may result in liquid fuel exiting the vent line and create a risk of fire.

Fix: On affected machines fit a new and rerouted vent pipe.

114 vehicles · built 12 Jun 2013 to 30 Apr 2014

On affected machines the Cargo box retaining bracket fasteners may become loose or dislodged under certain conditions.

Fix: Fit an improved Cargo box bracket and fasteners

• CREW: 34 vehicles · built 15 Apr 2014 to 25 Jun 2015
• RANGER XP: 34 vehicles · built 15 Apr 2014 to 25 Jun 2015

A side panel that may contact the exhaust manifold.This may pose a fire hazard.

Fix: On affected machines fit a modified side panel.

24 vehicles · built 29 May 2014 to 4 Oct 2016

Polaris Industries Inc. (Polaris) have issued a stop ride stop sale notice on a small number of 2016-2017 RZR and General vehicles. It has been identified that the brake master cylinder on these machine may have been contaminated during manufacture. This can cause the front brake circuit seal to swell. The swollen seal may cause unintended brake drag resulting in a potential fire and/or burn hazard.

Fix: Recall all affected machines to check the master cylinder and replace the master cylinder if found to be defective.

• GENERAL: 6 vehicles · built 2 Feb 2016 to 23 Jun 2016
• RZR: 6 vehicles · built 2 Feb 2016 to 23 Jun 2016

Polaris Industries Inc. (Polaris) have issued a stop ride stop sale notice on some model year 2016 RZR S 1000 and General vehicles. It has been identified the Engine ECU fitted to these machines have not been installed with a misfire detection calibration. This may allow unburned fuel to enter the exhaust system which can cause excessive exhaust heat that may pose a fire hazard.

Fix: Recall all affected machines and install new software.

• GENERAL: 2 vehicles · built 1 Dec 2015 to 15 Jun 2016
• RZR: 2 vehicles · built 1 Dec 2015 to 15 Jun 2016

The air box intake snorkel that may come in contact with the fuel rail or fuel line during operation. The resulting contact between the snorkel and fuel rail or fuel line may cause a fuel leak that may pose a fire hazard. The resulting issue could lead to a fuel leak which may pose a fire hazard.

Fix: Recall the machines that are likely to be affected and inspect the intake snorkel fuel rail and fuel line and replace them if they are damaged. A modified support bracket between the air box snorkel and the fuel rail will also be installed.

79 vehicles · built 25 Jul 2013 to 29 Sep 2016

Insufficient clearance between the fuel rail and the engine can result in abrasion of the fuel rail posing a potential fuel leak. A fuel leak in the presence of an ignition source may pose a fire hazard.

Fix: On affected machines.Check fuel line install a bracket and where necessary replace fuel rail.

219 vehicles · built 29 Jun 2013 to 29 Jun 2016

1. It is possible during production the brake pressure switch (brake light switch) may have been over torqued. This could result in a loss of brake fluid and subsequent reduction in braking performance which could cause a collision. 2. It is possible during production the fuel pipe may have been placed to close too the hood which resulted in insufficient clearance between the two. This could result in the abrasion of the fuel pipe which could leak. If this happens in the presence of an ignition source there will be a risk of fire. 3. It has been identified that the suspension swinging arm may not have been manufactured to the correct specification which affects its strength and could cause it to fail. If this occurs the directional control of the machine could be affected.

Fix: Recall all the affected machines to inspect check and if required replace the defective components.

14 vehicles · built 22 Apr 2014 to 26 Sep 2016

The Cargo-Box retaining bracket may become loose and dislodge.This may allow the exhaust to overheat a seat panel and may lead to fire. THE MANUFACTURER ADVISES NOT TO USE THE MACHINE.

Fix: On affected machines replace the Cargo-Box retaining Bracket.

• RANGER XP: 54 vehicles · built 25 Apr 2013 to 13 May 2014
• CREW XP: 54 vehicles · built 25 Apr 2013 to 13 May 2014

The engine may continue to run in an extreme over heat condition which can lead to the destruction of the engine and loss of oil and coolant. Additionally the fasteners used to attach the oil drain tube to the turbo system may loosen allowing a release of engine oil. The release of engine oil onto hot surfaces may pose a fire hazard.

Fix: Recall the machines that are likely to be affected and change the turbo drain tube and fastenings check and where necessary replace the heat shields replace the fasteners for the heat shield (where directed) insert the Owner�s Manual Addendum and re-flash the ECU. Where directed the Engine Temperature Sensing System will have to be checked.

21 vehicles · built 14 May 2015 to 4 Dec 2015

In the event of an ignition misfire unburned fuel can be routed into the exhaust system. Ignition misfire could cause elevated exhaust temperatures that may pose a fire hazard.

Fix: Recall the machines that are likely to be affected and download revised ECM calibration that includes engine misfire detection.

182 vehicles · built 6 Jun 2013 to 28 Apr 2016

There may be insufficient shielding between the engine exhaust and rearmost seat close-off panel which could lead to the seat close-off panel overheating and ultimately a fire hazard. Consumers should immediately stop using the recalled vehicles.

Fix: Recall the machines that are likely to be affected and fit a heat shield service kit.

186 vehicles · built 17 Sep 2013 to 7 Jun 2016

The fuse box seal could allow water intrusion into the fuse box which may create an electrical malfunction that could pose a fire hazard. Consumers should immediately stop using the recalled vehicles.

Fix: Recall the machines that are likely to be affected and fit a modified fuse box seal.

85 vehicles · built 15 Jul 2013 to 27 Jul 2015

The vehicles may have been manufactured with an improperly routed fuel tank vent line (i) having insufficient clearance to the exhaust pipe; (ii) which may cause it to become kinked. Consumers should immediately stop using the recalled vehicles. A fuel tank vent line with insufficient clearance to the exhaust pipe may pose a fire hazard. A kinked vent line can cause the fuel tank to build pressure and expand. The expansion of the fuel tank may result in contact of the spinning prop shaft which may result in a fuel leak.

Fix: Recall the machines that are likely to be affected and inspect the fuel tank vent line. Repair/reroute the vent line as necessary.

118 vehicles · built 22 Jul 2013 to 4 Nov 2015

The regulator could overheat and pose a fire hazard. Consumers should immediately stop using the recalled vehicles.

Fix: Recall the machines that are likely to be affected to inspect and where necessary repair the regulator fitment. Replace the regulator.

163 vehicles · built 3 Oct 2012 to 15 Feb 2016