PlainRecalls

CPSC, Polaris Industries Announce Recall of 900 Fusion, 900 RMK, and 900 Switchback Snowmobiles

Reported: July 28, 2005 Initiated: July 28, 2005 #05590 About 7,800 units

Polaris Industries Inc., of Medina, Minn. issued this CPSC recall on July 28, 2005. Classified as Moderate severity. Approximately About 7,800 units are affected. The recall was issued because: There are three separate issues involved in this safety recall: Front Suspension Spindle - The nut that fastens the upp…. This recall notice is sourced from official CPSC enforcement records. Below you will find the complete product description, hazard information, remedy instructions, and related recalls from the same manufacturer or product category.

Recall Insight

This CPSC action (record #05590) was formally reported on July 28, 2005. It is classified under Moderate severity, with a current status of Active. Polaris Industries Inc., of Medina, Minn. is listed as the recalling firm. Federal records indicate About 7,800 units are affected.

The documented reason for this recall is: 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 … Distribution information was not included in the agency filing, so consumers should assume broad potential exposure until the firm publishes point-of-sale details. The remedy documented by the agency is: Consumers should immediately stop using the snowmobile and contact their Polaris dealer to schedule a free repair. Polaris is directly notifying most owners about the recall. — consumers holding this product should act on that instruction rather than relying on general guidance.

To put this record in context, PlainRecalls indexes 83,949 recalls across the FDA, CPSC, NHTSA and USDA FSIS going back to 1995. Within the same product category, the database holds 6 closely related recalls. That clustering is a signal — repeated actions in a narrow category often indicate a systemic quality-control issue, a supplier-wide contamination, or a design defect that has propagated across product lines. This recall is roughly 21 years old; older recalls can remain relevant because many units enter resale, rental, and secondary-market channels where the original warning never reaches the end user. Always cross-check the recall number against the official agency page before relying on any summary.

Recall Distribution by Severity Class

Severity1Class I (Critical)Class II (Moderate)Class III (Low)
Recall Distribution by Severity Class

Severity

Moderate

Units Affected

About 7,800

Related Recalls

6

0 from same agency

Product Description

The recall includes model year 2005 Polaris "900 Fusion," "900 RMK," and "900 Switchback" snowmobiles with model numbers: S05PL8DSD, S05PM8DS(A)(B), S05PN8DS, S05PS8DS, S05PM8DS(A)(B)(C), S05PL8DS(A)(B)(C). The snowmobile model and serial number identification decal is located on the right-front side decal of the tunnel. The serial number is permanently stamped into the tunnel and the model number is embossed on the decal.

Reason for Recall

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.

Remedy

Consumers should immediately stop using the snowmobile and contact their Polaris dealer to schedule a free repair. Polaris is directly notifying most owners about the recall.

Recall Profile

Structured summary of the CPSC recall record
Attribute Value
Agency U.S. Consumer Product Safety Commission
Severity class Moderate
Status Active
Recall number 05590
Date reported July 28, 2005
Date initiated July 28, 2005
Recalling firm Polaris Industries Inc., of Medina, Minn.
Units affected About 7,800
Distribution Not disclosed

Profile values are sourced directly from the official CPSC enforcement record. Source: U.S. Consumer Product Safety Commission.

Scale of Impact

About 7,800 units affected — limited or regional distribution scale.

Regional (<10K units) ✓ This recall
Multi-state (10K – 100K units)
Large-scale (100K – 1M units)
Massive (≥1M units)

Bracket cutoffs follow federal recall-disclosure conventions; bar widths scale linearly within each bracket. Source: PlainRecalls analysis of U.S. Consumer Product Safety Commission filings.

Frequently Asked Questions

What product was recalled?
The recall includes model year 2005 Polaris "900 Fusion," "900 RMK," and "900 Switchback" snowmobiles with model numbers: S05PL8DSD, S05PM8DS(A)(B), S05PN8DS, S05PS8DS, S05PM8DS(A)(B)(C), S05PL8DS(A)(B)(C). The snowmobile model and serial number identification decal is located on the right-front side decal of the tunnel. The serial number is permanently stamped into the tunnel and the model number is embossed on the decal.. Recalled by Polaris Industries Inc., of Medina, Minn.. Units affected: About 7,800.
Why was this product recalled?
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.
What should consumers do?
Consumers should immediately stop using the snowmobile and contact their Polaris dealer to schedule a free repair. Polaris is directly notifying most owners about the recall.
Which agency issued this recall?
This recall was issued by the CPSC on July 28, 2005. Severity: Moderate. Recall number: 05590.
How do I check if my product is affected by a recall?
Check the product description and recall number (05590) against your product. Visit the official CPSC website for the most current information. You can also use our Recall Checker tool to search by product name or brand.
How do I report an injury from a recalled product?
Report injuries to the issuing agency: CPSC at SaferProducts.gov, NHTSA at nhtsa.gov/report-a-safety-problem, or FDA via MedWatch. Document the product (photos, model/serial numbers, purchase receipts) and seek medical attention. Injury reports help agencies track hazard patterns and may strengthen enforcement actions.

Recall Context

Product recalls are issued when a manufacturer, distributor, or federal agency determines that a product poses a safety risk to consumers. This recall is classified as moderate severity, indicating the product may cause temporary or medically reversible health consequences. Across PlainRecalls, we track 83,000+ recalls from FDA, CPSC, and NHTSA to help consumers stay informed and act quickly when safety issues arise.

Nearby Recalls in This Category

Other recalls in the same product category — useful for spotting patterns across the same defect class or manufacturer.

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Data Sources

Data as of 2025. Source: FDA, CPSC, NHTSA, USDA FSIS federal recall databases.

  • Source: FDA — Food and Drug Administration, openFDA Enforcement API (food, drug, and medical device recalls)
  • Source: CPSC — Consumer Product Safety Commission Recalls API (consumer product recalls and hazards)
  • Source: NHTSA — National Highway Traffic Safety Administration Recalls API (vehicle safety recalls)
  • Source: USDA FSIS — Food Safety and Inspection Service (meat, poultry, and egg product recalls)

Recall information is sourced from official federal agency databases. Always verify recall details with the issuing agency for the most current status. This information is for research and awareness purposes only.

All federal data sources used on this page

Source: Federal recall agencies (FDA, CPSC, NHTSA, USDA FSIS) Aggregated multi-agency recall feeds · 2024 Recall data normalized across federal agency feeds; severity classifications follow each agency's own taxonomy (FDA Class I/II/III; CPSC, NHTSA, USDA FSIS).