BRP Recalls Nearly 500 Can-Am Motorcycles Over High-Voltage Battery Defect

Bombardier Recreational Products Inc. (BRP) has announced a safety recall affecting nearly 500 of its 2025 Can-Am Origin and Pulse hybrid electric motorcycles due to a manufacturing defect that could pose significant safety risks. The issue stems from a faulty breather valve that may allow moisture or water to infiltrate the high-voltage battery system.

The defect, which was discovered during qualification tests on pre-production units in Canada, revealed that the breather valve might not seal properly due to inconsistencies in the thickness of the battery housing. This flaw could lead to vehicles losing power while in operation and, over time, may result in battery fires—even when the motorcycle is not in use. Although BRP has not received any reports of related accidents, fires, or injuries, the potential hazard has prompted a proactive recall.

Following the discovery on March 18, 2025, BRP halted shipments from its Mexico plant and initiated a full review of the issue. The investigation concluded that many battery housing covers were out of specification, leading to improperly clipped breather valves. On April 17, the company officially determined a recall was necessary to address the safety concern.

To remedy the defect, BRP will instruct dealers to install a redesigned protective plate with a rubber stopper that applies pressure to the breather valve, ensuring a secure seal. In some cases, the valve itself will also be replaced. All affected motorcycles were manufactured between May 2, 2024, and March 15, 2025, and remain under warranty. Dealer notifications began on April 29, 2025, with owner notifications scheduled from May 6 to May 27.

Article by multiple RFHC contributors, based upon information from a U.S. National Highway Traffic Safety Administration (NHTSA) safety recall report issued by Bombardier Recreational Products Inc.

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