Polaris Recalls Continue in 2025: Safety Hazards Persist for Off-Road Vehicles

Polaris has a long history of recalls over other potentially dangerous defects such as fire risks and others. Despite facing record fines and repeated warnings, multiple Polaris product lines are still the subject of recalls—including many issues in 2025 alone. The company’s Ranger, RZR, snowmobiles, Indian Motorcycles, and even helmets have all been flagged for a variety of risks, including fire hazards, ejections, crash risks, and inadequate protection in safety gear. Here is more information about the Polaris recalls and what to do if you’re a victim of injuries caused by a defective recreational off-road vehicle (ROV).

A history of ignoring safety hazards

In April 2018, Polaris agreed to pay a record penalty—$27.25 million—to settle charges that it failed to immediately notify federal safety officials about a fire hazard associated with its ROVs, which federal regulators have linked to at least one death and more than 180 fires.

One of the charges affected 133,000 vehicles, including model years 2013-2016 RZR 900 and model years 2014-2016 RZR 1000, that caught fire while consumers were driving which posed an obvious burn hazard to drivers and passengers. Polaris only reported the defects to the CPSC in April 2016, by which time there were already 150 fires, including one fire that killed a 15-year-old teenager and seriously injured 11 people.

Another charge included the Ranger XO 900 and Crew 900 vehicles, model years 2014-2015, whose heat shields became loose and fell off. This resulted in 36 reports of fires to Polaris, who made two design changes before finally informing the CPSC. For this, Polaris agreed to pay the penalty without admission of guilt, according to the Safety Research blog.

A story in the Tucson Sentinel reported that not only did Polaris not admit wrongdoing after consumers died, suffered serious burns, and experienced tremendous property damage, but the company also did not offer an apology for the fires or fatalities.

Today, over a decade after those dangerous models hit the market, the company is still the frequent subject of safety-related recalls.

2025 Polaris recalls: An ongoing problem

Here are several recalls listed on the company’s site so far this year:

Sept. 10, 2025—Ranger XP 1000 and Crew XP 1000 NorthStar Recall

The vehicle’s alternator cable/chassis harness is misrouting and may contact battery posts, causing cable insulation damage, possible electrical shorts, and fire hazards. About 5,600 vehicles are impacted globally. There have been five reports of sparking, smoke, or melting and one fire.

July 3, 2025—509 Tactical 3.0 Helmets (Polaris-branded and 509-branded)

These helmets fail to comply with certification standards and may not provide sufficient crash protection, increasing the risk of head injury. The recall applies to multiple youth and adult helmet sizes, sold in various colors.

June 18, 2025—Ranger XP Kinetic & Pro XD Kinetic Recall

Cracks in the charging system may lead to water intrusion, which can cause a short circuit while charging, leading to fire risks. About 7,100 vehicles are impacted globally. There were 47 reports of cracks, six reports of melting or fire, and four reports of smoke or sparking.

May 28, 2025—MATRYX Snowmobiles Recall (Patriot 650 & 850 engines)

The issue is that a drive clutch failure from post cracking can lead to the clutch or components detaching, causing serious injury risks. The recall impacts about 21,160 units globally. There have been 133 failures, including 12 where parts separated and two reported injuries.

May 15, 2025—Ranger XP 1000 NorthStar Recall

The improperly torqued lower seat belt anchor fasteners create a risk of belt detachment, which could lead to injuries in a crash. This recall impacts around 660 vehicles globally. There have been two reports of vehicles with loose fasteners and no reported injuries.

April 3, 2025—RZR Pro R / Pro R 4 Recall

Missing or loose fasteners in the ROPS (rollover protective structure) pillar joints can reduce rollover protection, increasing the injury risk to users. The recall applies to about 1,020 vehicles globally. There are two reported vehicles with missing fasteners and one with a loose fastener, but no reported injuries.

March 4, 2025—Indian Motorcycle Recall (Fuel Pump Defect)

Polaris’ on-road motorcycles are subject to a recall as well. The vehicles’ fuel pump wire defect creates a risk of pump failure and vehicle stalling, which may lead to a crash risk.

Jan. 16, 2025—Ranger XD 1500 & Crew XD 1500 Recall

The vehicles’ door handle actuators may stick, causing the doors to open unexpectedly, creating the risk of ejection or a crash. About 4,900 vehicles are impacted globally. There are 20 reports of doors opening unexpectedly. While there are no reported injuries, the risk of rider ejection shows how severe some of these defects can be.

What this means for off-road vehicle owners

Polaris recalls affect tens of thousands of units globally in 2025 alone, with serious possible risks ranging from fires to ejection. Defective safety equipment means that riders who believe they are taking steps to protect themselves might be left without the security they expect. Those who choose to use these products need to carefully consider the risks they are taking and keep a watchful eye for recalls impacting their vehicles. If you or a loved one sustained injuries because of a defective Polaris vehicle or another ROV, you need to speak to an attorney.

We need stronger safety standards

As of 2025, there are still no federal mandatory safety standards governing the design and manufacturing of ROVs. There are voluntary standards that the industry updated in response to the CPSC concerns related to rollovers, occupant retention, and handling. Still, other possible hazards, like debris penetration for example, are not covered by the updates.

Despite years of reports of dangers related to ROVs, the 2025 recalls illustrate that design and manufacturing defects persist. As a result, serious risks continue to surface. Consumers should not rely solely on voluntary compliance from the industry to ensure their safety. It’s important to stay vigilant and informed about new recalls.

If you have a vehicle that is subject to a recall, immediately stop use, follow interim safety steps, and contact Polaris dealers for free repairs or other resolutions. The Polaris site provides VIN lookup tools and hotlines for off-road and on-road recalls. Ignoring these warnings can expose riders to severe injury risks.

Legal help for victims of defective Polaris products

Defective products put consumer safety at risk. If you have been injured because of a product defect, the Georgia product liability attorneys at Harris Lowry Manton, LLP are here to fight for you. At Harris Lowry Manton, LLP, we stand up for the rights of clients injured by defective products. Our experienced team never backs down when facing negligent product manufacturers. We’re prepared to work to obtain compensation for your injuries. You may call us today or fill out our contact form to schedule a free consultation with one of our attorneys.