bombardier four-wheel ATVs

The reports, as CPSC published them

1. Hospital admission

   Made Apr 28, 2025 · , sent to the company May 1, 2025 · , published by CPSC May 22, 2025

   The product, in the report: bombardier ds650x 2005 ATV

   [REDACTED]

   Date: April 28, 2025

   To: U.S. Consumer Product Safety Commission (CPSC) Office of Compliance and Field Operations Washington, DC, USA

   Subject: Request for Review Regarding Recall Applicability and Potential Brake Failure in Bombardier DS650 ATVs (Model Years 20042005)

   Dear Sir/Madam,

   I am writing to formally request an investigation and technical review concerning the 2005 recall issued for the Bombardier DS650 all-terrain vehicles (ATVs), specifically addressing potential hidden defects relating to rear brake failure.

   The recall originally announced by CPSC and BRP (Bombardier Recreational Products) covered VIN ranges associated with improper lubrication of rear axle bearings, posing a risk of bearing failure and loss of vehicle control (CPSC Recall 2005). However, my ATV ([REDACTED]) was not listed within the published VIN range, despite being structurally and mechanically identical to models included in the recall.

   On October 7, 2007, while accelerating from second to third gear over a speed bump, the front end of my DS650 lifted sharply. Upon attempting to brake using the rear brake pedal, there was no braking response. The vehicle continued dragging on its rear wheels for approximately 30 meters until colliding with a curb and flipping over, resulting in serious personal injuries.

   Importantly, I only became aware of the existence of this recall within the past two weeks. At the time of the incident and for many years thereafter, the recall was never published or made available in Israel, as would be required under standard international product safety disclosure obligations. This lack of disclosure prevented me from addressing the defect through the recommended corrective measures.

   Subsequent investigations revealed the following key findings:

   The structure and rear axle assembly of my DS650 match the recalled models.

   The defect in rear axle bearing lubrication, as identified in the recall, can lead to pitting and spalling, causing microstructural failures that critically impair rear axle alignment.

   Misalignment or internal bearing failure under dynamic load conditions (such as a wheelie maneuver) directly compromises rear braking efficiency, causing brake disengagement or failure.

   Multiple user reports in ATV communities have documented rear brake inefficiencies in DS650 models.

   Technical standards (ASTM F2077, ISO 281, FMVSS 122) affirm that bearing failure can compromise braking function.

   Based on expert engineering analysis, there is a reasonable engineering probability that the accident resulted from the same bearing defect addressed in the original recall.

   Given the severity of the consequences and the structural similarities between my ATV and the recalled models, I respectfully request that the CPSC:

   Review whether the scope of the 2005 recall should be expanded to include additional VINs, including [REDACTED].

   Evaluate whether rear brake system failure could have been a consequence of the rear axle bearing defect cited in the original recall notice.

   Consider issuing a supplemental recall notice or a public safety bulletin if warranted.

   Attached to this letter are additional documents, technical reports, and expert opinions supporting the concerns raised.

   Thank you very much for your attention to this important safety matter. I look forward to your response and remain available to provide any further information required.

   Sincerely,

   [REDACTED]

   UPDATED ON 4/8/2026: [Summary of New and Relevant Information

   1. **Existence of a Known Safety Defect Prior to Vehicle Delivery**

   In March 2005, BRP issued an official recall in the United States addressing a defect in the rear axle bearing and sealing system. The recall documentation describes lubrication failures that may lead to accelerated bearing wear, rear axle misalignment, and potential brake malfunction.

   2. **Vehicle Delivered After Recall Without Disclosure or Remedy**

   Despite the recall being issued prior to delivery, my DS650 unit was delivered in Israel in May 2005 without any recall notification, disclosure, or preventive corrective action being applied.

   3. **Early Mechanical Symptoms Following Delivery**

   Within approximately two and a half months of delivery, abnormal rear axle play was detected during normal use. Repairs were carried out, including replacement of bearings and seals. These components were later discontinued by BRP, without any explanation or notification to consumers regarding potential defects or safety implications.

   4. **Accident Involving Rear Brake Failure**

   On October 18, 2007, a rear brake failure occurred during operation of the vehicle, directly resulting in a serious accident. The failure mechanism observed is consistent with the defect described in BRP’s 2005 recall documentation, involving lubrication failure, accelerated wear, and axle misalignment.

   5. **Additional Identical Accident Outside the Recall Scope**

   In addition to the vehicle referenced above, it is known that **another BRP DS650 ATV in Israel was involved in an accident with the same failure characteristics** as those described in the 2005 recall, namely rear axle bearing failure leading to loss of braking capability.

   Both vehicles involved in these accidents fall **outside the scope of the original recall**, due to the recall being limited to a specific market and a defined production series based on selected VIN ranges. As a result, **vehicles manufactured with the same or functionally identical rear axle bearing and sealing systems were excluded from the recall**, despite being exposed to the same safety defect.

   6. **Indication of a Systemic Safety Risk Created by Recall Limitation**

   The limitation of the recall to a specific market and VIN range constitutes a direct contributing factor to the involvement of at least two vehicles in serious accidents within the same market. This indicates that the defect is not confined to a single production batch or geographic market, but represents a broader manufacturing and/or design safety issue affecting additional vehicles that were not included in the recall.]

   Model

   DS650X

   Where

   Israel: Other

   Who was involved

   Age 19, Male

   The reporter’s relation to them

   Self

   As this report names them

   Brand bombardier, made or sold by BRP US Inc. (Bombardier Recreational Products)

   How badly, in CPSC’s words

   Injury, Hospital Admission

2. No one hurt

   Made Nov 4, 2013 · , sent to the company Nov 20, 2013 · , published by CPSC Dec 5, 2013

   The product, in the report: ATV 4 wheeler 2005

   The consumer stated that he drove his ATV for approximately 10 minutes and shut it off. He stated that approximately an hour later he saw smoke being emitted by the ATV. He stated that the smoke reached approximately 10’ high and a flame on top of the regulator that was approximately 3”. The consumer stated that he immediately unhooked the battery and the fire went out.

   The consumer stated that no one was injured.

   The consumer stated that he purchased a new regulator and the ATV was working properly after it was replaced. The consumer stated that paid $220 for the new regulator.

   The consumer stated that he contacted the manufacturer and they informed him that his ATV was not on a recall.

   The consumer stated that he believes that this product should be investigated due to the fire and burn hazard that it poses to consumers.

   Model

   Rally 200 (2005 Model)

   UPC

   Unknown

   Serial number

   Unknown

   Bought from

   Brunkan Equipment, Iowa

   Bought

   Aug 1, 2013, about then

   Where

   Pyersville, Iowa: Home/Apartment/Condominium

   Who was involved

   Unspecified

   The reporter’s relation to them

   Unspecified

   As this report names them

   Brand Bombardier (BRP), made or sold by BRP US Inc. (Bombardier Recreational Products)

   How badly, in CPSC’s words

   Incident, No Injury

CPSC’s disclaimer

Sources