Polaris RZR Pro XP 4 / RZR Turbo R 4 fuel-pump joint leak fire hazard (CPSC 2023, expanded August 2023)

Polaris · 2021–2023 · Published May 6, 2026

Polaris recall of MY2021-2023 RZR Pro XP 4 and MY2022-2023 RZR Turbo R 4 ROVs where a fuel leak can occur at the fuel pump assembly joint on the fuel tank, in close proximity to a hot surface, posing a fire hazard. ~12,300 US units (originally ~600, expanded August 2023); 5 fuel leaks; 1 fire.

Details

## Affected machines

This bulletin covers Polaris RZR Pro XP 4 and Turbo R 4 four-seat recreational off-road vehicles.

### Affected models and model years

- Model Year **2021-2023** RZR **Pro XP 4** (Premium, Sport, Ultimate)
- Model Year **2022-2023** RZR **Turbo R 4**

The recalled vehicles were sold in: black, blue, graphite, gray, navy blue, titanium metallic, metallic, orange, red, silver, white, green. POLARIS is stamped on the front grille; POLARIS and RZR are printed on the sides; the model name is also printed on the side of the chassis. The VIN is on the vehicle's frame in the left rear wheel well.

The recalled vehicles were sold in a four-seat configuration.

About **20,330 US units** (plus ~330 Canada). Some of these vehicles were previously recalled in November 2020 for a related but distinct fuel-system defect; the August 2023 announcement expanded the affected population.

## Issue

A **fuel leak** can occur at the fuel pump assembly joint on the fuel tank, **in close proximity to a hot surface**, posing a fire hazard.

Reported field incidents at time of recall:
- 5 fuel leaks
- 1 fire

## What to do

1. Verify the model and VIN against Polaris's published affected list at https://www.polaris.com/en-us/off-road-recalls/.
2. **Stop using the ROV immediately.**
3. Contact a Polaris dealer to schedule a free repair (fuel-tank assembly replacement).
4. Polaris is contacting registered owners directly.

## Hazard

Severity is rated **critical**:
- Fuel leak in close proximity to a hot surface
- 1 confirmed fire
- Polaris off-road vehicles have a documented history of fire-related incidents

## Related bulletins

This is the first Polaris bulletin in the TractorNuity library. Other Polaris bulletins in this migration:
- TNB02600132 - RZR XP Turbo / Turbo S clutch failure fire+injury
- TNB02600133 - Ranger XP 1000 (MY2018-2020) clutch belt fuel-line damage fire
- TNB02600134 - RZR XP / Turbo / GENERAL XP steering wheel separation crash
- TNB02600135 - Ranger XP 1000 / RZR Pro XP / Pro XD fuel pump connector leak fire

## Source

- U.S. Consumer Product Safety Commission, "Polaris Recalls RZR Pro XP and Turbo R Recreational Off-Road Vehicles Due to Fire Hazard (Recall Alert)," August 2023.
- CPSC, "Polaris Recalls RZR Recreational Off-Road Vehicles Due to Fire Hazard (Recall Alert)," 2023.
- Polaris recall page: https://www.polaris.com/en-us/off-road-recalls/

Affected equipment

Polaris RZR Pro XP (RZR Pro XP)
Polaris RZR Pro XP 4 (RZR Pro XP)
Polaris RZR Turbo R 4 (RZR Turbo R)

Sources

Important: TractorNuity makes a best effort to track known defects and concerns via publicly available data. TractorNuity's ownership group however does not have relationships with manufactures to be alerted to defects as they are identified. Regular maintenance and safe operation of any equipment is always the sole responsibility of the operator.

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