ATV Accident Litigation: Polaris RZR Fire Injuries and Deaths

The Polaris RZR is a popular side-by-side off-road vehicle known for its versatility across various terrains. First manufactured in 2007 under the name the Ranger RZR, the Polaris RZR has been at the center of numerous safety complaints, predominately fire-related incidents, for more than a decade, raising significant safety concerns and legal challenges for Polaris Industries and its controversial recreational off-highway vehicle.

Major complaints and concerns about the Polaris RZR include:

• Fire Hazards

– Exhaust Heat Issues: The proximity of the exhaust manifold to other components has been a recurring problem. Reports show that heat from the exhaust manifold often initiates fires by melting nearby components like fuel vent tubing.

– Structural Deficiencies: Defective shock absorbers and suspension systems have also contributed to rollovers and subsequent fires.

• Injuries and Deaths

Polaris issued its first RZR recall in 2013 due to heat damage concerns, yet did not adequately address the problem. In 2016, Polaris expanded its recall to include 166,000 RZR models after acknowledging that the fire hazard was more severe than initially reported. By then, Polaris had knowledge of over 160 RZR fires that caused serious property damage including a multi-acre fire, at least 11 burn injuries, and the tragic death of a 15 year-old passenger.

Despite the numerous recalls and reported dangers, the changes Polaris made to the RZR were insufficient. In 2024, a tragic incident involving a Polaris RZR resulted in the deaths of four young adults after the vehicle rolled over and burst into flames. The families subsequently filed a lawsuit against Polaris for knowingly selling defective vehicles. To this day, there continue to be reports that some vehicles continue to catch fire even after undergoing recommended fixes.

Regulatory Penalties and Litigation Against Polaris

The US Consumer Product Safety Commission (CPSC) identified multiple defects in the Polaris Razor that posed substantial hazards, including misrouted fuel lines, loose fuel rail mounting fasteners, and high-temperature conditions near the exhaust manifold. Despite receiving numerous reports of fires and injuries, Polaris waited until February 2016 to file a full report about the defects in its RZR models. This delay violated Section 19(a)(4) of the Consumer Product Safety Act, which requires manufacturers to immediately notify the CPSC of product defects that pose unreasonable risks.

The agency alleged that Polaris knowingly violated federal safety laws by delaying its reports on fire risks. In 2018, Polaris agreed to pay the CPSC a $27.25 million civil penalty for failing to promptly report defects that posed fire risks. This fine remains one of the largest in CPSC history. Despite this penalty, reports of fires persist, highlighting ongoing safety concerns.

Litigation Against Polaris Industries

Polaris has faced numerous lawsuits from consumers and families affected by RZR fires.

Class Action Lawsuits: Several lawsuits seek class-action status on behalf of injury victims and their families. These cases argue that Polaris concealed knowledge of defects and failed to take adequate corrective action. The lawsuit seeks to hold Polaris responsible for the alleged dangerous design and to compensate those who have been harmed.

Individual Claims: There have been multiple lawsuits against Polaris related to serious burns alleging negligence on the part of Polaris for continuing to market its RZR model despite their knowledge of its dangers. In 2023, four adults in their 20s died when their Polaris RZR rolled over and ignited in flames. Families of victims have accused Polaris of “negligent, reckless, and deliberate” decisions to sell defective vehicles despite knowing about their fire hazards.

Both types of litigation include some or all the following charges:

• Defective Design: Plaintiffs argue that design flaws in Polaris RZRs, such as overheating engines and poorly routed fuel lines, make the vehicles prone to spontaneous fires.
• Negligence: Lawsuits allege that Polaris was aware of these defects as early as 2011 but continued selling the vehicles without adequate fixes.
• Failure to Warn: Plaintiffs claim that Polaris failed to notify consumers about the risks or delayed issuing recalls despite having evidence of fire hazards.
• Concealment of Evidence: Some lawsuits accuse Polaris of attempting to cover up safety issues by settling cases confidentially and withholding critical information from the public, including attempting to shield internal communications under attorney-client privilege to mitigate culpability.

While Polaris has issued recalls, claiming their actions represent an “abundance of caution,” their actions have been insufficient given the scale and persistence of the problem. In December 2017, the CPSC and Polaris issued a joint statement acknowledging that repaired vehicles were still catching fire and that newer models not included in earlier recalls were also affected. A 2022 recall for Model Year 2021-2022 RZR models was due to fuel leaks near hot surfaces. And a 2023 recall for Model Year two different 2021 RZR XP Turbo models was owed to clutch failures that could result in fires.

Clearly, Polaris is more concerned with their bottom line than with public safety.

What To Do If You’re Injured in a Polaris RZR or other ATV Accident

I’m Ed Smith with AutoAccident.com, an off-road vehicle accident law firm in Sacramento, CA. As an accident injury attorney, it’s clear to me that Polaris has prioritized profits over consumer safety by delaying recalls, downplaying risks, and failing to perform adequate repairs to its RZR ATV. If you or a loved one was injured while riding in a Polaris RZR due to a fire, a tip-over, or other accident, you need a law firm with the massive resources needed to support your case including the capacity to:

• Collect millions of pages of internal Polaris documents
• Conduct extensive depositions with current and former employees
• Develop expert analyses and model redesigns to demonstrate alleged defects
• Determine not only your current damages, such as pain, suffering, lost income and medical care, but also the projected future losses related to lost work, ongoing rehabilitative care, and the impact on your family and social life.

When a company like Polaris allows repeated incidents to occur and inadequately addresses the root causes of their products’ flaws, it does more than erode the public trust – it places lives at serious risk. That’s why more comprehensive solutions may be needed, including punitive damages designed to force the company to: 

• Take greater care with their ATV design and development
• Immediately report defects and perform recalls
• Include transparency of past problems so consumers can make informed choices
• Do more to promote consumer safety

Despite recalls and corrective actions, Polaris ROV fires have persisted. Reports indicate that even newer models and repaired vehicles continue to catch fire under certain conditions. That’s why your case may be instrumental in forcing the imposition of stricter penalties and mandatory design changes rather than relying on voluntary compliance from Polaris.

Don’t Wait to File Your Claim!

It’s important to note that most off-road vehicle accident cases fall under product liability claims, which means they can have filing limitations as short as two years. That means if you file later than the time limits set by your state, you’re out of luck.

If you or someone you care about was injured in a Polaris RZR accident, don’t wait. Contact the experienced legal team of AutoAccident.com today. We have decades of experience with ATV accident injury cases, and have garnered multimillion dollar awards for clients injured by faulty product designs, manufacturers’ failure to warn consumers, and other liability claims.

Located in California with a legal reach across the US, the law firm of AutoAccident.com is a trusted leader in accident injury litigation, with 10.0 ratings by Avvo and Justia, 5-star ratings on Yelp and Google, and membership in the Million Dollar Forum and the National Association of Distinguished Counsel.

If you live anywhere in the US and a Polaris RZR or any other brand ATV left you or a loved one hurt, disabled, disfigured, or with a diminished quality of life, we’re here to help.

Call us now at 916.921.6400 or toll-free at 800.404.5400 for free, friendly advice.