Polaris RZR recalls

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

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.

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.

2 vehicles · built 1 Dec 2015 to 15 Jun 2016

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

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

In the event of an engine misfire unburned fuel can be routed into the exhaust system which can cause excessive exhaust heat that may pose a fire hazard. Consumers should immediately stop using the affected vehicles.

Fix: Recall the machines that are likely to be affected and install a revised EU calibration to detect misfire and prevent excessive exhaust temperatures.

69 vehicles · built 8 Jul 2014 to 15 Feb 2016

The vehicles may have been manufactured with heat shields that are inadequate. The resulting issue could lead to the cab or cargo box overheating which may pose a fire hazard. Revised shields will also provide additional protection from flammable liquid spills that may pose a separate fire hazard. Consumers should immediately stop using the affected vehicles.

Fix: Recall the machines that are likely to be affected and inspect and replace the existing heat shielding. Install additional heat shielding.

118 vehicles · built 22 Jul 2013 to 10 Mar 2016

Affected vehicles may have been manufactured with turbocharger oil drain line fasteners that do not meet the torque specification. This could lead to oil leaking onto the engine and exhaust head pipe creating a potential risk of fire. Consumers should immediately stop using the recalled vehicles and contact their local Polaris dealer.

Fix: Check and if necessary retorque pipe retaining bolts.

5 vehicles · built 14 May 2014 to 14 Oct 2015