An improperly manufactured clutch component can cause the engine braking feature to fail, resulting in unexpected vehicle motion, posing a crash hazard.
Polaris Industries Inc., of Medina , Minn.
Class II - Moderate
The throttle can fail to return to the idle position after the engine stalls and is restarted in gear without switching the key to the off position due to a software problem, causing the vehicle to accelerate suddenly, posing a crash hazard to the user.
Class II - Moderate
The rear brake line can become punctured causing the brakes to fail, posing a collision and crash hazard.
Class II - Moderate
An incorrectly wired chassis harness can cause an incorrect throttle control signal to the electric drive motor, which can cause the vehicle to accelerate unexpectedly, posing a crash hazard.
Class II - Moderate
The brakes can fail, posing crash and injury hazards.
Class II - Moderate
The front lower control arms can separate, posing a crash hazard.
Class II - Moderate
In the event of a high-speed rollover, the vehicle's rollover protection structure (ROPS) can fracture, providing inadequate protection during a rollover.
Class II - Moderate
The front suspension lower ball joint can separate over time, posing a crash hazard.
Class I - Dangerous
The utility vehicle's exhaust header pipe can crack, posing burn and fire hazards.
Class I - Dangerous
The utility vehicle's exhaust header pipe can crack, posing fire and burn hazards.
Class I - Dangerous
The return fuel line can be improperly secured which can cause fuel to leak, posing a fire hazard.
Class II - Moderate
The steering wheel shaft can shift and detach while in use, resulting in a loss of control and crash hazard.
Class I - Dangerous
The exhaust header pipe can crack and release hot exhaust gases into the engine compartment, posing fire and burn hazards.
Class II - Moderate
Inconsistent tire pressure information can result in improperly-inflated tires, posing a crash hazard.
Class II - Moderate
The throttle release switch can fail, posing a crash hazard.
Class I - Dangerous
Fuel can leak into the headlight pod, posing fuel leak and fire hazards.
Class II - Moderate
The front brake can detach, posing crash and injury hazards.
Class II - Moderate
A weld on the steering post can separate, resulting in loss of steering control, posing a crash hazard.
Class I - Dangerous
A heat shield can fall off the vehicle, posing fire and burn hazards to riders.
Class II - Moderate
The vehicles' throttle cable can melt on the exhaust pipe and fail to operate properly. This can cause the rider to lose control, posing a crash hazard.
Class I - Dangerous
The firewall behind the driver and passenger seats can overheat and melt, posing a burn hazard to consumers.
Class II - Moderate
The recreational vehicle's throttle can fail to operate properly, which can cause the vehicle's rider to lose control, posing a crash hazard.
Class I - Dangerous
The bolt attaching the front, lower left shock can fail and cause the operator to lose control of the vehicle. This poses a serious hazard of injury or death.
Class I - Dangerous
The front suspension ball joint stem can separate from the steering knuckle and cause the rider to lose steering control, posing a risk of injury or death to riders.
Class I - Dangerous
An electrical short can lead to overheating in the rear tail light wiring harnesses, posing a fire hazard to consumers.
Class I - Dangerous
The valve assembly can fail in freezing temperatures, causing oil to leak into the exhaust system. This could pose a fire and burn hazard to the rider.
Class II - Moderate
Bolts on the rear suspension can break causing the rail tip to become dislodged and interfere with the snowmobile's track. This can cause the track to lock up and the rider to lose control of the snowmobile, posing a risk of injury.
Class II - Moderate
The insulation of the electrical cord for the engine and battery heaters can fail during cold temperatures, posing an electric shock hazard to consumers.
Class I - Dangerous
The fuel lines on the snowmobiles can make contact with one another, which could result in a fuel leak. This can pose a fire hazard to consumers.
Class I - Dangerous
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.
Class I - Dangerous
The ATVs can have defective Electronic Control Modules (ECM) that overheat, posing a fire and burn hazard to riders.
Class I - Dangerous
A retention bolt can come loose, causing the rear wheels to lock up, which poses a risk of serious injury to the rider.
Class I - Dangerous
The ATVs can have defective Electronic Control Modules (ECM) that overheat, posing a fire and burn hazard to riders.
Class I - Dangerous
The utility vehicle's fuel tank can leak, posing fire and burn hazards to consumers.
Class I - Dangerous
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.
Class I - Dangerous
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.
Class I - Dangerous
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.
Class II - Moderate
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.
Class II - Moderate
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.
Class I - Dangerous
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.
Class I - Dangerous
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.
Class I - Dangerous
Some 2004.5 and 2005 Model Year Sportsman, Scrambler 500 ATVs, Trail Boss and Magnum 330 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.
Class I - Dangerous
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.
Class I - Dangerous
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.
Class II - Moderate
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.
Class I - Dangerous
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.
Class II - Moderate
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.
Class I - Dangerous
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.
Class I - Dangerous
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.
Class I - Dangerous
The accessory skis sold for Polaris snowmobiles could break, resulting in injury or death.
Class I - Dangerous
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.
Class II - Moderate
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.
Class I - Dangerous
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.