BRP Recalls Snowmobiles Due to Fire Hazard (Recall Alert)

What was recalled

In early March 2022, the U.S. Consumer Product Safety Commission (CPSC) announced a significant safety recall involving specific models of Ski-Doo snowmobiles manufactured by BRP (Bombardier Recreational Products). This action affects a substantial number of vehicles that were sold to consumers across the United States, primarily during the winter seasons leading up to 2022. The core issue centers on the fuel system design in certain Expedition series models equipped with the 900 ACE turbo engine. If you own one of these specific snowmobiles, it is crucial to identify whether your vehicle falls within this defined group before taking any further action.

The recall specifically targets Ski-Doo Expedition LE, SE, and SWT snowmobiles from model years 2020, 2021, and 2022. These vehicles were marketed in a variety of colors to suit different consumer preferences, but the color of the bodywork does not determine whether your unit is affected; only the model year and engine type matter. The common denominator across all recalled units is the installation of the 900 ACE turbo engine. This particular engine configuration is central to the safety concern, as the fuel tank venting system in these models was designed in a way that poses a risk under certain conditions.

To help you verify if your snowmobile is part of this recall, BRP has provided clear identification markers. The brand name "Ski-Doo" and the specific model name are printed directly on the side panels of the vehicles, making them easily visible from the outside. However, the most definitive way to confirm eligibility is by checking the Vehicle Identification Number (VIN). This VIN is located on a decal situated on the right-hand side of the tunnel, underneath the seat. You will need to lift your seat to access this information.

The following specific models are included in this safety alert:

• 2020 Model Year: Ski-Doo Expedition SE 900 ACE Turbo and Ski-Doo Expedition LE 900 ACE Turbo
• 2021 Model Year: Ski-Doo Expedition SE 900 ACE Turbo, Ski-Doo Expedition LE 900 ACE Turbo, and Ski-Doo Expedition SWT 900 ACE Turbo
• 2022 Model Year: Ski-Doo Expedition SE 900 ACE Turbo, Ski-Doo Expedition LE 900 ACE Turbo, and Ski-Doo Expedition SWT 900 ACE Turbo

If your snowmobile matches any of the combinations listed above, it is part of this recall. The vehicles were sold new through authorized Ski-Doo dealerships nationwide. BRP has stated that they are contacting all known purchasers directly to coordinate repairs, but relying solely on direct contact may not be sufficient if you have purchased a used unit or if your contact information has changed. Therefore, proactive verification using the VIN is strongly recommended.

The hazard, explained

At the heart of this recall is a specific mechanical interaction between fuel delivery and heat management that can create a dangerous situation under certain conditions. The recalled Ski-Doo snowmobiles utilize a 900 ACE turbo engine, which generates significant operational heat. Normally, the fuel tank vent system is designed to manage pressure within the fuel tank safely. However, in this specific configuration, the design allows fuel to leak from the fuel tank vent onto hot components of the vehicle.

This leakage does not typically occur during standard operation on flat ground. Instead, the risk emerges when the snowmobile is tilted or flipped over. When a snowmobile tips onto its side or is inverted—perhaps due to rough terrain, an accident, or improper handling—the orientation of the fuel tank changes relative to the vent outlet. In this altered position, fuel can escape through the vent and drip directly onto nearby hot engine parts or exhaust components.

The danger lies in the combination of three elements: flammable fuel, a source of ignition (the hot components), and an oxygen-rich environment. When fuel leaks onto these hot surfaces, it can vaporize rapidly. If the temperature of those components exceeds the auto-ignition point of the fuel vapor, a fire can start without any external spark. This is particularly concerning because it can happen quickly and in areas that are not immediately visible to the rider, especially if they are wearing heavy winter gear or if visibility is poor due to snow spray.

While no injuries have been reported so far, BRP has received five confirmed reports of fires related to this fuel leaking issue. These incidents underscore the real-world potential for harm. A fire on a snowmobile is not just a property loss; it poses an immediate threat to personal safety. Riders may be unable to extinguish the fire while operating the vehicle, and if the snowmobile tips over during a fire, escape routes can become blocked by flames or smoke. Even if the fire does not cause a major crash, the heat and smoke can lead to burns or inhalation injuries.

Understanding this mechanism helps explain why the remedy is so critical. The fix involves changing the routing and exit location of the fuel tank vent, ensuring that any potential leaks do not reach hot surfaces. Additionally, a protective plate will be installed to provide an extra layer of defense against heat transfer. By addressing the physical path of the fuel, BRP aims to eliminate the possibility of the fuel contacting ignition sources, thereby removing the hazard entirely.

This type of hazard is not unique to snowmobiles but is common in various internal combustion engine vehicles. Engineers must carefully balance fuel system pressure with heat management to prevent such scenarios. In this case, the specific tilt angle or flip condition creates a temporary but dangerous pathway for fuel that was not adequately accounted for in the original design’s safety margins. Consumers should recognize that even minor tilting can trigger this leak, making immediate cessation of use essential until the free repair is completed.

Who is most at risk

The primary group facing risk in this recall consists of owners and operators of specific Ski-Doo Expedition models manufactured between 2020 and 2022. Specifically, these are the Expedition LE, SE, and SWT variants equipped with the 900 ACE turbo engine. Because the hazard is tied directly to the mechanical configuration of the fuel tank vent system, any individual who owns or regularly operates one of these seven specific model-year combinations is potentially at risk. The risk is not limited to professional guides or experienced racers; it extends to recreational users who take their snowmobiles out on trails, through deep powder, or across uneven terrain where the vehicle is likely to encounter significant bumps, ruts, or sudden stops.

The nature of this hazard creates a unique vulnerability for anyone operating the snowmobile in conditions that cause the vehicle to tilt or flip over. Unlike standard fire risks that might arise from electrical shorts or engine overheating during normal operation, this issue is triggered by the physical orientation of the machine. When a snowmobile tips onto its side or back—whether due to hitting a large obstacle, sliding down a steep bank, or simply losing balance on ice—the fuel can leak from the tank vent directly onto hot components below. This means that the risk is highest for those who engage in aggressive riding styles or who frequent challenging terrain where rollovers are more common. It also affects users who may park their vehicles on uneven ground, causing a persistent tilt even when the engine is off but potentially hot.

In terms of demographic vulnerability, snowmobile owners tend to be adults who enjoy winter sports and outdoor recreation. While there is no specific data suggesting that children or the elderly are disproportionately affected by this particular defect, the consequences of a fuel-fire incident are severe for any rider. A fire occurring while the vehicle is in motion can lead to immediate loss of control, resulting in secondary accidents such as collisions with trees, rocks, or other vehicles. For solo riders, who make up a significant portion of the snowmobile demographic, the risk is compounded because there is no companion to assist in an emergency evacuation. Although BRP has received five reports of fires without any reported injuries, the potential for serious burn injuries or smoke inhalation remains high if the fuel ignites while a rider is seated on the vehicle. Therefore, all owners of these specific models should treat the risk seriously, regardless of their age or experience level, because the mechanism of failure relies on physics and geography rather than user error alone.

It is also important to note that the risk persists even if you have not yet experienced a malfunction. The defect is inherent in the design of the fuel vent routing and exit location for these specific models. Until the free repair is performed, which includes changing the vent routing and installing a protective plate, the potential for fuel to drip onto hot parts remains active. This makes proactive identification and immediate cessation of use critical for all owners, as waiting for a warning sign or a minor leak to occur is not a safe strategy. The silence of the incident report so far—no injuries yet—does not diminish the severity of the hazard; it simply means that luck has not yet run out for the five known cases. Every owner in this group is part of the at-risk population until the safety modification is completed.

How to tell if you have the recalled item

Before you take any action or contact a dealer, it is critical to confirm whether your specific snowmobile is part of this recall. Because BRP manufactures many different models and years, checking the exact identification numbers is the only way to be certain. The recall affects a very specific subset of Ski-Doo Expedition series snowmobiles. If your vehicle does not match the details below, it is likely not included in this particular safety alert, but you should always verify with an official source if you are unsure.

First, identify the model year and name printed on the side panels of your vehicle. This recall covers only the 2020, 2021, and 2022 Expedition LE, SE, and SWT models. Crucially, these models must be equipped with a 900 ACE turbo engine. If your snowmobile has a different engine type or is from a year outside this range (such as a 2019 or 2023 model), it is not part of this specific recall. The brand name "Ski-Doo" and the specific model designation are clearly printed on the side panels, making them easy to spot when you are standing next to your vehicle.

The most definitive way to confirm eligibility is by locating your Vehicle Identification Number (VIN). You will find the VIN decal on the right-hand side of the tunnel, directly underneath the seat. Once you have located this number, you can cross-reference it with the official recall list or use the online lookup tool provided by BRP. The following specific configurations are included in this recall:

• 2020 Ski-Doo Expedition SE 900 ACE Turbo
• 2020 Ski-Doo Expedition LE 900 ACE Turbo
• 2021 Ski-Doo Expedition SE 900 ACE Turbo
• 2021 Ski-Doo Expedition LE 900 ACE Turbo
• 2021 Ski-Doo Expedition SWT 900 ACE Turbo
• 2022 Ski-Doo Expedition SE 900 ACE Turbo
• 2022 Ski-Doo Expedition LE 900 ACE Turbo
• 2022 Ski-Doo Expedition SWT 900 ACE Turbo

Please note that these vehicles were sold in a variety of colors, so the color of your snowmobile does not determine whether it is recalled. The key factors are the model year, the specific Expedition trim (LE, SE, or SWT), and the presence of the 900 ACE turbo engine. If you have one of the models listed above, you should stop using the vehicle immediately and proceed to the remedy section.

What to do — step by step

Your refund, repair, or replacement options

If you own one of the recalled Ski-Doo snowmobiles, it is important to know upfront that a cash refund for the vehicle itself is not part of this recall remedy. Instead, the Consumer Product Safety Commission (CPSC) and BRP have arranged for a comprehensive, free repair service designed to eliminate the fire hazard at its source. This approach ensures that your investment in the machine remains intact while significantly enhancing its safety profile. The core of the remedy involves a mechanical modification performed by authorized Ski-Doo dealers, so you will not need to pay for parts or labor.

The specific repair process is quite thorough and addresses the root cause of the fuel leak. When your snowmobile is at the dealer, they will change the routing and the exit location of the fuel tank vent. This adjustment prevents fuel from dripping onto hot engine components when the vehicle is tilted or flipped over—a common occurrence during snowmobiling. In addition to rerouting the vent, the dealer will install a protective plate. This plate acts as a critical barrier, further reducing the risk that any potential fuel contact with hot surfaces could lead to a fire. Because this repair requires specialized knowledge of the Ski-Doo engine systems, particularly those with the 900 ACE turbo engine, it is essential that you do not attempt to fix this issue yourself.

You might be wondering how you will be notified or if you need to take the first step in contacting a dealer. BRP has stated that they are proactively reaching out to all known purchasers directly. Their goal is to coordinate the free repair with local dealers, making the process as seamless as possible for you. However, if you have not received communication from BRP yet, or if you simply want to verify your vehicle’s status, you should take the initiative. The recall applies specifically to 2020, 2021, and 2022 Expedition LE, SE, and SWT models equipped with the 900 ACE turbo engine. Since these vehicles were sold in a variety of colors, visual identification alone is not enough; you must verify your Vehicle Identification Number (VIN) against the recall list.

To get started, you have two primary options for getting more information or scheduling your repair. You can call the BRP toll-free number at 888-272-9222. Customer service representatives are available from 8 a.m. to 8 p.m. ET, Monday through Sunday, which provides flexible timing for busy schedules. Alternatively, you can visit the official Ski-Doo website. Navigate to the "Owner Zone" and look for the maintenance or safety recalls section. You can also go directly to https://www.ski-doo.com/us/en/owner-zone/maintenance/safety-recalls/fuel-may-drip-on-hot-components-potential-fire-hazard.html. On the main Ski-Doo page, click on "Safety Recall" at the bottom of the page for detailed information and dealer locator tools.

Until your vehicle is repaired, please stop using it immediately. The risk of fire is real, with BRP having received five reports of fires related to this specific fuel leak issue. While no injuries have been reported so far, the potential danger is significant. Do not ride your snowmobile until the dealer has confirmed that the vent routing has been changed and the protective plate has been installed. This free repair is the only official remedy offered for this recall, ensuring your safety without costing you anything out of pocket.

What can happen if you ignore it

It is completely understandable to feel reluctant to stop using a cherished piece of recreational equipment, especially when the weather is perfect for a ride and the snowmobile appears to be running just fine. However, ignoring this specific safety recall carries serious, immediate risks that go far beyond a simple mechanical inconvenience. The core issue here is not a minor wear-and-tear problem; it is a fundamental flaw in how fuel is managed within the vehicle’s system under stress conditions. When you continue to operate these recalled Ski-Doo models without the mandated repair, you are leaving yourself vulnerable to a scenario that can escalate from a mechanical failure to a life-threatening emergency in seconds.

The hazard described by the Consumer Product Safety Commission (CPSC) is precise and dangerous: fuel can leak from the fuel tank vent onto hot components when the snowmobile tilts or flips over. Snowmobiling often involves navigating uneven terrain, sudden stops, and sharp turns, all of which cause the vehicle to lean significantly. If you ignore the recall, you are essentially betting that your next ride will not involve a tilt steep enough to trigger this leak. But when it does happen, the consequences are severe. The leaked fuel does not just drip away; it comes into contact with hot engine parts or exhaust components that are already at ignition temperatures. This creates an immediate fire hazard. As noted in the recall facts, BRP has already received five reports of fires related to this specific issue. While no injuries have been reported so far, the potential for severe burns, smoke inhalation, and vehicle loss is real and present every time you start the engine without the fix.

Beyond the immediate danger of fire, continuing to use the recalled unit exposes you to significant financial and logistical burdens. If a fire occurs due to non-compliance with the recall, standard insurance policies may scrutinize whether negligence played a role in the damage. Furthermore, repairing a snowmobile after it has been damaged by fire is exponentially more expensive than the free repair being offered now. You would be looking at hundreds, if not thousands, of dollars in replacement parts, labor, and potential total loss of the vehicle. The remedy provided—changing the routing and exit location of the fuel tank vent and installing a protective plate—is designed to prevent this exact chain of events. By waiting, you are not only risking your safety but also forfeiting a free, professional service that addresses the root cause of the danger.

Please remember that recalls are issued based on rigorous testing and incident data. The fact that five fires have already occurred is a clear warning sign that this is not a theoretical risk. Do not wait for an accident to validate the urgency of this recall. Stop using the snowmobile immediately, contact BRP or your dealer, and schedule the free repair. It is a quick, cost-free step that ensures you can enjoy your winter adventures with peace of mind, rather than fear.

Staying safe: broader tips