What was recalled
The Consumer Product Safety Commission (CPSC) has issued a recall affecting specific accessory LED Light Kits manufactured by Excel Industries. This action, announced on August 27, 2026, targets a particular set of aftermarket lighting products designed to enhance visibility for heavy-duty landscaping and agricultural equipment. The recalled items are not standard headlights sold separately, but rather complete accessory kits intended to be installed on specific brands of ride-on mowers. If you purchased these kits to upgrade the front lighting of your machine, it is important to understand exactly which physical components are involved in this safety advisory.
The core of the recalled product consists of two LED Light Bars contained within a single accessory kit. These light bars are designed to function as headlights for Hustler or BigDog ride-on mowers. Physically, the light bars themselves are constructed from clear plastic and measure 6 inches wide by ¾ of an inch tall. Each bar features both a white wire and a black wire, terminating in an orange plug at the end, which is used to connect the unit to the mower’s electrical system. The kit also includes the necessary mounting hardware, specifically a steel bracket that is available in either black or yellow. This bracket is designed to attach securely to the footrest area at the very front of the mower, holding the two light bars in place as a dual-headlight setup.
This recall is significant because it involves the entire assembly—the lights, the wires, and the mounting brackets—as a single functional unit. The products were marketed as accessories for Hustler and BigDog mowers, meaning they are not universal fitments but are tied to specific vehicle platforms. While the provided recall documentation does not list the exact number of units distributed or specify the precise retail locations where these kits were sold, it is critical for owners of these specific mower brands to inspect their equipment. If your Hustler or BigDog mower currently has a front-mounted lighting accessory that matches this description—two clear plastic light bars attached via a steel bracket to the footrest—you should consider your unit potentially affected until you can verify its status through the official channels provided by Excel Industries.
- Brand: Excel Industries
- Product Type: Accessory LED Light Kit (includes two LED Light Bars and mounting components)
Front headlights for Hustler or BigDog ride-on mowers - Physical Description: Clear plastic light bars (6 inches wide, ¾ inch tall) with white/black wires and an orange plug; black or yellow steel mounting bracket
The hazard, explained
When we talk about a "fire hazard" in the context of vehicle accessories, it is easy to imagine dramatic scenes of flames erupting uncontrollably. However, the reality of how these incidents occur is often more subtle and insidious, rooted in basic principles of electrical engineering and heat management. In this specific recall involving Excel Industries’ accessory LED Light Kits, the core issue is that the light bars are prone to overheating or producing flames under normal operating conditions. To understand why this matters, we need to look at what happens inside those clear plastic housings when they fail.
LED (Light Emitting Diode) technology is generally efficient, but it still generates heat. Properly designed lighting systems for heavy equipment include components like heat sinks, proper insulation, and voltage regulators to ensure that the electrical current flows safely and that any generated heat is dissipated effectively. When a light bar overheats, it usually means that one of these safeguards has failed or was insufficient. The electricity flowing through the wires and connectors encounters resistance. If the wiring is not rated for the amperage being drawn, or if connections are loose, that resistance turns electrical energy into excessive thermal energy rather than just light.
In the case of these recalled kits, the mechanism of harm begins with this excess heat. The LED Light Bars in question measure 6 inches wide and ¾ of an inch tall, encased in clear plastic. Plastic is a poor conductor of heat compared to metals like aluminum or steel. If the internal components generate more heat than the plastic housing can safely manage—or if the plastic itself degrades due to heat exposure—it can soften, melt, or become flammable. Once the protective casing fails, the exposed electrical wires and diodes are in direct contact with combustible materials, such as the mower’s deck, debris, or even the mounting bracket itself.
This is how a simple malfunction transforms into a serious injury risk. The "producing flames" aspect mentioned in the recall indicates that the heat has reached the ignition point of nearby materials. Because these lights are mounted at the front of ride-on mowers like Hustler or BigDog models, they are often positioned near grass clippings, dry leaves, or other organic debris that accumulates during use. If a light bar overheats while the mower is running, it can ignite this debris. Even if the mower is parked, a residual hot component can smolder and eventually burst into flame, especially if fuel lines or electrical wiring are nearby.
The risk of serious injury comes from two main factors: speed and location. Fire in an engine compartment or near the operator’s feet can spread rapidly, trapping the user or causing burns before they can react. Furthermore, fires involving electrical components can release toxic fumes, adding a layer of respiratory danger to the physical burn hazard. While no incidents have been reported with this specific batch yet, the potential for harm is significant because the failure mode involves uncontrolled heat generation in an environment already prone to combustion risks.
Understanding this mechanism underscores why stopping use immediately is not just a precaution but a necessity. You are effectively removing a potential ignition source from your equipment. By addressing the overheating issue through the recall remedy, you are eliminating the possibility of that heat accumulating to dangerous levels, ensuring that your mower remains a tool for work rather than a source of danger.
Who is most at risk
The individuals most directly affected by this recall are the owners and operators of Hustler or BigDog ride-on mowers who have purchased the specific accessory LED Light Kit as an add-on feature. These kits are designed to be mounted at the front of the mower, typically on the footrest area, to serve as headlights for improved visibility during early morning or late evening mowing sessions. If you own one of these specific commercial-grade turf equipment units and installed this light kit, your safety is directly compromised until the remedy is applied.
While the recall notice does not report any incidents of fire at this time, the nature of the hazard—a potential for overheating or producing flames—creates a unique risk profile for several groups. The primary group at risk includes adult operators who may be using these mowers in residential or light commercial settings. These users often operate equipment in close proximity to dry vegetation, wood chips, mulch, and other combustible materials that are common on lawns and landscaping sites. An electrical fire starting at the front of a ride-on mower can rapidly ignite surrounding debris, especially if the operator is not immediately aware of the smoke or heat buildup.
Children and family members present in the yard also face significant vulnerability. Ride-on mowers are frequently used in residential environments where children may be playing nearby. If a light kit fails and ignites, the resulting fire could spread quickly to nearby structures, play equipment, or landscaping features where children might be located. The risk is compounded by the fact that electrical fires can produce toxic fumes before becoming visible flames, posing an inhalation hazard to anyone in the immediate vicinity who does not recognize the source of the smoke.
Additionally, elderly homeowners or those with limited mobility may be at higher risk due to potential delays in evacuation. If a fire occurs while they are operating the machine, their ability to quickly dismount and escape could be hindered by the sudden heat, smoke, or panic induced by the malfunction. Furthermore, because these light kits are installed on the footrest area, the operator’s legs are in close proximity to the potential ignition source, increasing the risk of serious burn injuries if the plastic housing melts or catches fire while the mower is in operation.
It is also important to note that commercial landscapers who use BigDog mowers for professional jobs face heightened liability and safety concerns. A fire on a worksite not only endangers the operator but also poses risks to clients, other workers, and neighboring properties. The concentration of flammable materials like grass clippings in collection bags or windrows can act as fuel, turning a small electrical fault into a large-scale emergency.
In summary, while no incidents have been reported yet, the potential for serious injury from fire makes this recall critical for all owners of these specific light kits. The risk is not just about equipment damage; it is about preventing personal harm to operators, bystanders, and families in residential or commercial settings. Immediate action is essential to mitigate these risks.
How to tell if you have the recalled item
Identifying whether your equipment is part of this specific recall requires a careful physical inspection of the accessory light kit installed on your mower. Because these kits are aftermarket accessories rather than standard factory-installed components, they may not be immediately obvious at first glance. You need to look for a distinct setup that deviates from the typical lighting configuration of your machine. The recall specifically targets accessory LED Light Kits designed for use on Hustler or BigDog ride-on mowers. If you did not purchase or install an aftermarket light kit yourself, it is highly unlikely you are affected by this issue.
Start by examining the front of your mower, specifically the footrest area. The recalled product features a black or yellow steel mounting bracket that attaches directly to the mower footrest at the front. This bracket is designed to hold two LED Light Bars in place, functioning as headlights. If you see a bracket holding two separate light bars rather than integrated, molded headlights built into the body of the mower, you may have the recalled item.
Next, inspect the light bars themselves to confirm the specific physical characteristics described in the safety advisory. The LED Light Bars in this recall are constructed with clear plastic housings. They measure exactly 6 inches in width and ¾ of an inch in height. While the overall size is a key identifier, you should also look at the wiring configuration. Each light bar will have two wires: one white wire and one black wire. At the end of these wires, you will find an orange plug used for connection. The combination of the clear plastic casing, the specific 6-inch by ¾-inch dimensions, and the distinctive orange plug is critical for accurate identification.
If you are unsure whether your kit matches this description, do not attempt to install or remove the unit yourself if you are uncomfortable doing so. Instead, contact Excel Industries directly using the toll-free number provided in the recall notice (888-848-6038) or visit their website at www.hustlerturf.com/product-recall or www.bigdogmowerco.com/product-recall. You can also navigate to www.hustlerturf.com, click on “Service & Parts,” and select “Product Recalls” from the drop-down menu to verify your specific model against the recall database. Taking these steps ensures you are not mistaken about the presence of the hazard.
What to do — step by step
If you own an Excel Industries accessory LED Light Kit designed for Hustler or BigDog ride-on mowers, your immediate priority is to eliminate the risk of fire before it can cause harm. The recall notice from the Consumer Product Safety Commission (CPSC) makes this clear: you must stop using these light kits immediately. Do not wait for a convenient time to turn them off, and do not assume they are safe simply because they have worked without issue in the past. The hazard involves the light bars potentially overheating or producing flames, which poses a serious injury risk. By ceasing use right now, you are taking the most critical first step toward protecting your home, your property, and your family from potential harm.
The next phase of this process involves coordinating a return for a full refund. The remedy outlined by Excel Industries is straightforward but requires specific action on your part. You need to contact the dealer where you originally purchased the light kit. This point-of-sale connection is vital because they are equipped to handle the logistics of the return and issue your refund once the product is received. When you reach out to them, inform them that you are participating in this specific safety recall. They will guide you through their internal process for accepting the returned item and processing your money back to you.
You might be wondering about the physical removal of the unit, especially if it is already installed on your mower. The good news is that you have flexibility here. You can choose to have the light kit removed at your local dealer during the return process. This option takes the physical labor out of your hands and ensures the item is handled professionally. Alternatively, if you are comfortable with basic mechanical tasks, you may remove the light kit at your residence. The recall information confirms that removal at home is an acceptable first step before you bring the unit to the dealer or arrange for its return. This flexibility is designed to make the process as least disruptive as possible for you.
If you have questions about the removal process, need help locating your original dealer, or want confirmation that your specific model is included in this recall, Excel Industries has established direct channels for consumer support. You can call their toll-free number at 888-848-6038. Their representatives are available from 8 a.m. to 5 p.m., Monday through Friday, Eastern Time. This is the best place to start if you need verbal guidance or have specific concerns about your unit.
In addition to phone support, you can reach out via email at safetyadvisory@sbdinc.com. Email is often useful if you prefer to document your communication or if you have complex questions that require detailed answers. For those who prefer self-service options, Excel Industries has dedicated online portals for this recall. You can visit www.hustlerturf.com/product-recall or www.bigdogmowerco.com/product-recall directly. If you are on the main Hustler Turf website at www.hustlerturf.com, navigate to the “Service & Parts” section and select “Product Recalls” from the drop-down menu. These digital resources provide official confirmation and further details without requiring a phone call.
Finally, please remember that this recall is not just about paperwork; it is about safety. The fact that no incidents have been reported yet does not mean the risk is nonexistent. Overheating components can fail unpredictably. By following these steps—stopping use, contacting your dealer, and securing a refund—you are ensuring that a potentially dangerous product is removed from your property entirely. Take this seriously, but know that the process is designed to be simple and fully compensated. Your peace of mind is worth the few hours it takes to resolve this.
Your refund, repair, or replacement options
If you have determined that you own one of the recalled accessory LED Light Kits from Excel Industries, the good news is that the company has established a clear and straightforward path to resolve the issue. Unlike some recalls that require you to mail parts back to a central warehouse or wait for complex authorization codes, this remedy is designed to be handled directly through your point-of-sale dealers. This approach leverages the existing relationship between the customer and the dealer who likely sold them the mower or the light kit in the first place. The primary remedy offered is a full refund upon the return of the defective light kit. There is no mention of a repair option or a replacement with an upgraded model in the current recall notice; instead, the focus is entirely on removing the hazardous item from your property and returning your money.
To initiate this process, you must contact the dealer where you originally purchased the product. This is a crucial step because the dealer acts as the intermediary for both receiving the returned item and processing the financial reimbursement. When you reach out to them, be prepared to explain that you are participating in the safety recall due to the fire hazard associated with the light bars overheating or producing flames. The dealer will instruct you on how to return the kit. It is important to note that the physical removal of the light kit does not necessarily need to happen at the dealership. If the light kit has already been installed on your Hustler or BigDog ride-on mower, you have two convenient options for its removal. You can choose to bring the mower to your local dealer, where they can remove the unit and handle the return process for you. Alternatively, if you are comfortable doing so, you can remove the light kit at your own residence before taking it to the dealer.
If removing the light kit yourself is more convenient, remember that these kits are attached via a black or yellow steel mounting bracket that connects to the mower footrest. Once you have detached the unit, ensure you keep all components together—the two LED Light Bars and any associated kit parts—as you will need to return them in full to receive your refund. After the dealer receives the returned item, they will issue your refund. While the recall notice does not specify a timeline for when the money will appear in your account, dealing directly with the point-of-sale location typically ensures a faster resolution than waiting on mail-in processing.
If you need further assistance or cannot locate your original dealer, Excel Industries has provided direct consumer support channels. You can reach them toll-free at 888-848-6038 between 8 a.m. and 5 p.m., Monday through Friday, Eastern Time. They are also available via email at safetyadvisory@sbdinc.com or online at www.hustlerturf.com/product-recall, www.bigdogmowerco.com/product-recall, or by navigating to the “Service & Parts” and then “Product Recalls” section on www.hustlerturf.com. These resources are there to help you navigate the return process smoothly, ensuring you don’t have to deal with a dangerous product any longer.
What can happen if you ignore it
It is easy to look at a piece of equipment failure as an inconvenience rather than a threat, especially when the item in question is simply a set of headlights on a riding mower. However, ignoring this specific recall carries consequences that extend far beyond a broken light or a voided warranty. The core issue with these Excel Industries LED Light Kits is not merely that they stop working; it is that they become active sources of ignition. When the light bars overheat or produce flames, you are no longer dealing with a malfunctioning accessory but with a potential fire hazard in your immediate vicinity.
The real-world danger here is twofold: the risk to personal safety and the risk to property. Because these kits are mounted on the front footrest of Hustler or BigDog ride-on mowers, they are positioned directly above the operator’s legs and knees while driving. If a light bar were to overheat significantly enough to ignite its own casing or nearby materials, the heat would be directed downward toward the user. This poses a severe risk of serious injury, including deep burns to the skin and underlying tissue, which can occur in seconds before the fire is even visibly large. There is no time to react when an electrical component fails catastrophically under load.
Beyond personal injury, the potential for property damage is substantial. Riding mowers are often used near homes, sheds, or dry vegetation. A fire originating from the front of the mower can quickly spread to the fuel tank, the engine’s oil reservoir, or the surrounding landscape if you are mowing in dry conditions. Even if no fires have been officially reported to the CPSC as of this recall date, the absence of reported incidents does not mean the risk is theoretical. It simply means that lucky breaks have occurred so far. Electrical fires are unpredictable; they can start small and smolder unnoticed before flaring up into a full blaze.
Continuing to use these kits also puts you in a vulnerable position legally and financially. By ignoring the manufacturer’s directive to stop use, you assume full liability for any resulting damage or injury. Insurance claims related to fires caused by known, recalled defects that were not addressed can sometimes be contested if it is proven that the owner was aware of the hazard but chose to ignore it. The remedy offered—a full refund upon return—is designed to remove this risk entirely. Choosing to keep the kit keeps you in the line of fire for a problem that has already been identified and resolved by the manufacturer. Do not gamble with heat, flame, and proximity to your body when a simple call to Excel Industries can eliminate the danger completely.
Staying safe: broader tips
While this specific recall addresses a known defect in certain Excel Industries LED light kits, the underlying principle of electrical safety on outdoor power equipment applies to all ride-on mowers and similar machinery. When you are working with high-power accessories attached to heavy-duty vehicles, understanding how electricity interacts with heat and vibration is key to preventing accidents before they happen. One of the most common causes of electrical fires in outdoor equipment is not just faulty wiring, but poor connections that loosen over time due to engine vibration. As a mower vibrates across uneven terrain, connectors can pull apart slightly, creating resistance. This resistance generates heat at the connection point, which can eventually melt insulation or ignite nearby combustible materials like dried grass clippings or dust. Therefore, regularly inspecting all accessory wiring for fraying, cracking, or loose plugs is a vital habit for any owner.
Proper installation and strain relief are equally critical. When adding aftermarket lights or accessories, always ensure that wires are routed away from hot engine components, sharp metal edges, and moving parts. Use high-quality wire loom or conduit to protect cables from chafing against the mower’s frame. If you are installing a light kit yourself, never bypass fuses or use wiring that is not rated for the amperage draw of the device. Using undersized wires can cause them to overheat even if the component itself functions correctly. Additionally, ensure that all mounts and brackets are securely fastened using the hardware provided by the manufacturer; loose components can swing into rotating parts or create short circuits by grounding against the chassis unexpectedly.
Beyond physical installation, be mindful of your environment. Many fires involving outdoor equipment start when electrical sparks meet dry vegetation. Always clear the area around your mower’s intake and exhaust systems of dry leaves, grass, and debris before starting the engine. If you notice any burning smell, flickering lights, or unusual heat coming from an accessory while operating your machine, shut it off immediately and allow it to cool completely before investigating. Do not attempt to repair damaged electrical components with standard household tape; use automotive-grade heat shrink tubing or connectors designed for high-vibration environments.
Finally, stay informed about safety updates for all your equipment, not just when you suspect a problem. Check the Consumer Product Safety Commission (CPSC) website and manufacturer portals periodically for recall notices. Manufacturers often discover issues in the field that require proactive solutions. By staying engaged with these resources and treating your mower’s electrical system with the same respect as its mechanical parts, you significantly reduce the risk of injury or property damage. Remember, a little bit of preventive maintenance goes a long way in ensuring that your tools remain safe helpers rather than potential hazards.