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Safety Recall - 2007 Outlaw 525 ATV -Potential Fuel Leak Due to Fuel Valve

Dear Polaris ATV Owner:


In cooperation with the U.S. Consumer Product Safety Commission (CPSC), Polaris Industries Inc. is voluntarily recalling all 2007 Outlaw 525 ATVs produced between August 21, 2006 and February 7, 2007. Our records indicate that you are still the current registered owner of a potentially affected unit.


This letter is to notify you that Polaris has determined some Model Year 2007 Outlaw 525 ATVs produced between August 21, 2006 and February 7, 2007 may have been manufactured with loose fuel valve mounting inserts within the fuel tank. Polaris has identified that the holes receiving the threaded inserts were sized too large on some of the fuel tanks. This condition could allow the threaded inserts to pull out of the fuel valve attachment plate and may develop fuel leaks at the fuel valve mounting area due to insufficient retention of the threaded inserts. If this condition is present, a fuel leak would occur.


A fuel leak at the fuel tank shut-off valve would allow fuel to escape from the fuel tank and create a fire hazard. Failure of this component may lead to serious personal injury to the operator.




Your authorized Polaris ATV dealer has been issued Safety Bulletin ATV-07-02. This Safety Bulletin instructs your dealer to replace the fuel tank assembly. Please contact an authorized Polaris ATV dealer immediately to arrange a time to have the repair performed to your ATV. This work will be performed at no charge to you.


This notice was mailed to you according to our most current registration information. While your Polaris ATV dealer is in the best posi- tion to answer your questions, if you have any questions your dealer cannot address, you may call our Customer Service Department at 1-888-704-5290. If you need assistance contacting a Polaris Dealer, please call 1-800-POLARIS or visit the Polaris web site at


We apologize for any inconvenience this has caused you.




Laurie Rengel

Manager, Service Dealer Development & Warranty