No Longer Part Of Our ATV Tours – Polaris RZR XP 1000: Recalls and Reliability Issues

When the Polaris RZR side-by-sides burst on the off-roading scene in 2007, they were the first vehicles to meet federal trail regulations that established a 50 inch width limit on ATVs, helping to establish Polaris as an industry leader in side-by-sides. But with recurring problems and recalls issued for several of their models, it’s been a tough few years for Polaris.

Among those recalls are recent versions of the RZR, those game-changing side-by-sides that took 2007 by storm. In April 2016 Polaris recalled RZR 900 and 1000 models from 2013–2016, adding up to more than 133,000 vehicles in total. There are a few different issues that caused Polaris to issue the recall, but they each have the potential to cause fire. More than 160 RZR related fires have been reported to Polaris, including one that resulted in the death of a rider, and 19 others causing burns ranging from third to first degree. As part of the recall, Polaris identified a few key defects that can cause fires, including:
misrouted fuel tank vent lines
engine misfires
exhaust heat
faulty voltage regulators
leaky fuel box seals
For anyone who has been following the RZR line, this news won’t come as a complete surprise. In 2015, the RZR 900 and 1000 models for that year were recalled due to issues with fuel tank vent lines and reports of vehicle fires, and the more recent RZR recall just seems to build on these previously noted problems.
RZRs have been known in the past as some of the best handling side-by-sides on the market, but testing the limits of that handling has caused problems for some riders. A top-heavy frame in the RZR XP 1000 models from 2015 and ‘16 has caused complaints about excessive body roll from some, and other drivers report roll-over incidents. While almost any off-road vehicle has the potential to roll-over depending on how and where it’s being operated, drivers expect that machines are designed to reduce the chances of these accidents.
Aside from the fuel line problems and risk of fire or roll-overs, some less dangerous but still frustrating problems have been associated with the 2015 and 2016 RZR 1000 models. The clutch intake tends to bring in dust that can cause problems in your machine. But with or without dust intake issues, clutch replacement is one of the most frequent repairs needed on these machines, as both the primary and secondary clutches have been plagued by problems.
Unfortunately for Polaris, the recalls just keep on coming. The most recent, in March 2017, involved Sportsman 850 and 1000 ATVs from 2015 and ’16, with fire and burn hazards again being cited as the reason behind the recall. Owners of any recalled ATV are advised to stop using their vehicles immediately and contact Polaris to schedule repairs.
Safety should always be the primary concern of ATV and side-by-side operators and passengers. Issues like these can be frustrating and dangerous, but they help us to remember to pay close attention to our machines, and always ride safe.
2018-04-05T19:19:21+00:00 April 4th, 2017|9 Comments


  1. Gabe June 20, 2018 at 7:40 pm - Reply

    You have a picture of a CanAm in your photo feature. Seems a bit misleading, doesn’t it?

    • Cassie July 3, 2018 at 12:44 pm - Reply

      Hi Gabe, You seem like a nice guy. Not seeing the CanAm photo feature but would be more than happy for you to show us. And yes, I would fully agree with you, however, there is intentionally misleading and cause of an error. If you do show the CanAm, I can promise you it was HIGHLY likely it was our webmaster we fired and somehow it slipped through.

      We appreciate your taking the time to help us build a reputable company.

      The Vort Team

  2. Ryan August 12, 2018 at 10:17 pm - Reply

    No issues with my Polaris RZR 1000. Bottom line…. don’t take a 90 degree turn on any side by side at 40mph. If you are thinking of buying one… know your product and how it runs. Practice safe but fun as hell riding and you will be fine.

  3. Dan September 7, 2018 at 5:23 pm - Reply

    Which new performance side-by-sides do you recommend?

    • Cassie January 16, 2019 at 12:01 am - Reply

      Dan, great question. What kind of terrain are you using your side by side in?
      From our experience with Polaris and Wildcat, Mel says the RZR is hands down the best option for durability in mountainous terrain like we have. Sorry for the late reply! We hope to hear back from you if you have made a decision and purchased your machine!

  4. Lisa Simmons December 2, 2018 at 11:05 am - Reply

    Purchased our rzr 1000 about 6 months ago husband and son went riding yesterday after stopping by the dealership because of battery dead and a code coming up on dash dealer said it was a bad voltage regulator the machine was over charging they replaced the part sent my family on there way 3 hrs after riding my husband calls me in tears our highlighter was in flames and burnt to a crisp. What the hell!!! We will be at the dealer first thing in the morning to get to the bottom. Thank God my husband and son was able to get off and not get hurt. Wanted to warn others about this machine as I see it has multiple cases including ourselves now of catching on fire. Owners please be aware and safe !!

    • Cassie January 16, 2019 at 12:07 am - Reply

      We are so sorry to hear this happened to your family. We appreciate your taking the time to address this situation on this blog post and be a knowledgeable source to our readers and customers. Did Polaris make things right and did you find out what the cause was?

  5. TJ Sullivan April 28, 2019 at 2:08 am - Reply

    We have a 2016 Rzr 1000S and have numerous problems with it going into ‘limp mode’ EVERY time we take it off road. Just on today’s trip it happened 7 times!!!! Have taken it to our local dealer several times and they haven’t been able to stop it from happening!! PLEASE help!!! Any advice is Greatly appreciated!!!!!

    • Cassie May 28, 2019 at 7:25 pm - Reply

      HI TJ, thank you for reaching out. We are sorry your 2016 Polaris is having problems. We will pass your problem on to the owner and see if he has time to provide support.

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