Polaris Recalls

Hazard: Cracks could form in the starter ring-gear and cause the ring-gear to fracture into several pieces. The broken pieces could be propelled out of the chassis of the machine at high speed, causing serious injury or death to the rider and/or bystanders.

Hazard: The ATVs can have defective Electronic Control Modules (ECM) that overheat, posing a fire and burn hazard to riders.

Hazard: A retention bolt can come loose, causing the rear wheels to lock up, which poses a risk of serious injury to the rider.

Hazard: The ATVs can have defective Electronic Control Modules (ECM) that overheat, posing a fire and burn hazard to riders.

Hazard: The utility vehicle's fuel tank can leak, posing fire and burn hazards to consumers.

Hazard: The fuel tank filler neck can crack and separate allowing fuel or fuel vapors to leak from the fuel tank. This poses a fire hazard to consumers.

Hazard: The recalled ATVs may have a loose fuel valve within the fuel tank, which could cause a fuel leak and pose a fire hazard to riders.

Hazard: The steering posts can break in the area where the handlebar attaches to the steering post. This can result in loss of steering control, resulting in a crash and/or serious injury to the operator.

Hazard: The ATV's front bearing carrier can fail due to an insufficient amount of material thickness in the area where the lower a-arm and ball joint are attached, which can result in a loss of control and a crash and/or serious injury to the operator.

Hazard: The right and left front suspension shock towers can separate due to inadequate welding during the manufacturing process. Separation of the welded joints can result in stiffer steering or the shock mount failing suddenly, causing the rider to lose control of the snowmobile and crash.

Hazard: The fastener torque securing the starter motor to the engine crankcase may not have been accurately applied during the manufacture of these snowmobiles or during the installation of an accessory starter. An improperly torqued starter motor fastener bolt may become loose and fall out, allowing the bolt to interfere with the lower steering drag link. This could allow the consumer to experience a loss of steering control.

Hazard: The fuel tank filler neck on these snowmobiles can crack. A crack in the filler neck area may cause the filler neck to separate from the fuel tank. A crack or filler neck separation may allow fuel or fuel vapors to escape from the fuel tank, posing a fire hazard.

Hazard: There are three separate issues involved in this safety recall: Front Suspension Spindle - The nut that fastens the upper control arm ball joint to the suspension spindle can loosen. If this occurs, continued operation could allow the spindle to break and release the upper control arm, posing a risk of loss of control of the vehicle. Fuel Tank Chaffing - The fuel tanks can contact the chassis along the bulkheads, leading to wear on the tank walls. This could pose a fuel leakage and possible fire hazard to consumers. Gasket - The gasket sealing the fuel pump assembly to the tank can develop cracks. This poses a risk of fuel leakage and fire hazard to consumers.

Hazard: The fuel tank filler neck may develop a crack at the base where the filler neck meets the fuel tank assembly. This may cause the neck to separate from the fuel tank assembly and allow fuel to escape from the tank, potentially creating a fire hazard.

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.

Hazard: The snowmobile wiring harness may be routed in a way that could disconnect the engine stop switch and the throttle safety switch connector. If this connector becomes unplugged, the engine stop and the throttle safety switches will no longer function. This could pose a possible crash hazard. However, the keyed ignition switch will continue to function and will shut down the vehicle when the key is in the OFF position. The thumb warmer and right-hand warmer could also become unplugged under these harness-routing conditions.

Hazard: The fuel connections between the fuel line and the fuel pump and fuel filter can leak. Failure of the fuel connection can result in leaking fuel and a possible fire, which can result in severe injury or death. In addition, the drive shaft may have been incorrectly heat treated, resulting in brittle drive shafts that could fail at lower loads than the shafts were originally designed to meet. Failure of the drive shaft can result in a loss of braking of the snowmobile and severe injury or death.

Hazard: The lower steering shaft assembly may have a missing or misplaced weld that connects the steering wheel to the steering gear box assembly. If a weld is missing or misplaced, the lower steering shaft assembly could fail, causing the operator to lose control of the vehicle.

Hazard: The throttle cable may bind when the handlebars are turned full left or full right, resulting in an increase in engine speed and unintended vehicle acceleration. In addition, the fuel line may rub against the vehicle chassis, resulting in a fuel line leak, which could be a fire hazard.

Hazard: The front brake lines can crack and leak brake fluid, possibly resulting in loss of braking capability. This could result in severe injury or death.

Hazard: The accessory skis sold for Polaris snowmobiles could break, resulting in injury or death.

Hazard: Damage to the fuel tank grommet can cause a fuel leak, posing a serious fire hazard to consumers.

Hazard: The ATVs may have loose or leaking oil cooler line clamps, that can release hot pressurized oil. This may lead to thermal burns, to engine failure due to oil pressure loss and, in rare circumstances, could cause a vehicle fire.

Hazard: The mounting bolts on the front brake calipers were not tightened to the specified torque value. This may cause the bolts to loosen or fall out during operation, resulting in brake failure. This could result in severe injury or death.

Hazard: On all models, the brake pad may separate from the backing plate, which could cause brake failure. The brake pads will be replaced on all of the models. On model numbers S02NX4CS and S02NX4CSR the brake disc rivets may shear, which could cause brake failure. On these models, the brake disc and the brake pads will be replaced.

Hazard: The problem with the RANGER vehicles and UTVs involves the swing arm, which is part of the rear suspension. During operation of the vehicle, the pivot bolts of the swing arm can loosen and fall out. If this happens, the swing arm can become partially disconnected from the frame. This can result in the vehicle losing power, because the drivetrain connection to the wheels is no longer maintained. If this were to occur, the loss of power and resulting swing arm disorientation could cause the operator to lose control of the vehicle, resulting in injury to the operator.

Hazard: Screws in the ATV's manual transmission can loosen, causing the rear wheels to lock. This can cause the driver to lose control of the ATV and crash, possibly resulting in injury or death.

Hazard: The throttles on these ATVs can stick, preventing the ATV from slowing down when released. This can cause the vehicle to lose control and crash, resulting in severe injury or death.