Bombardier Recreational Products (BRP) is recalling 398 model-year 2025 Can-Am Origin electric motorcycles after determining that the front brake caliper support may fail under repeated hard braking. NHTSA Campaign Number 26V220, filed April 7, 2026, carries a “Do Not Drive” consumer advisory. The defect stems from an error in BRP’s finite element analysis that understated the fatigue risk in the component, and no crashes or injuries have been reported.
Highlights
- 398 units affected: All 2025 Can-Am Origin electric motorcycles produced between May 2, 2024, and June 17, 2025
- Root cause: Incorrect input data in BRP’s finite element analysis led to an understated fatigue threshold in the front brake caliper support
- Consumer advisory: NHTSA has issued a “Do Not Drive / Park Outside” notice pending repair
- Remedy: Dealers will install a caliper support reinforcement kit at no charge; parts availability dates are pending
Defect and Investigation Details
The recall centers on the front brake caliper support, a structural component manufactured by KYB Manufacturing Taiwan Co. The support may develop a fatigue crack after repeated hard or emergency braking, ultimately causing a complete loss of front braking capability.
BRP’s investigation traced the failure to an error in the input data used during finite element analysis. That error caused the FEA model to underestimate the cumulative stress on the caliper support, allowing a fatigue failure at a lower threshold than the design intended.
The issue first surfaced on January 19 and 29, 2026, during ABS calibration testing conducted at a supplier facility on a model-year 2027 motorcycle fitted with higher-grip on-road tires. Two front brake caliper support failures occurred during those tests. No field incidents or injuries preceded the discovery.
Tire Type Accelerates Risk
BRP noted that tire choice affects how quickly the fatigue condition develops. The Can-Am Origin ships from the factory with dual-purpose tires suited to its dual-sport design. Owners who have swapped to on-road tires may experience higher braking forces that accelerate the fatigue cycle. BRP stated that on-road tires increase the potential for hard braking and therefore speed up the failure progression.
Recall Timeline and Remedy
BRP determined on March 31, 2026, that sufficient evidence existed to proceed with a safety recall. The corrective action involves installing a caliper support reinforcement kit on the front brake caliper support at authorized dealers, free of charge.
Key dates for affected owners:
- Dealer notification: April 14, 2026
- Owner notification letters: Scheduled for May 14, 2026
- VIN search availability: April 21, 2026, via NHTSA.gov
- Parts availability: BRP will announce timing through its dealer network
The recall also carries a “Do Not Drive / Park Outside” consumer advisory, signaling that NHTSA considers the defect a significant safety risk. Owners are urged not to ride affected motorcycles until the reinforcement kit has been installed.
Production has been paused and will resume once reinforcement kits are integrated into the manufacturing process. Vehicles not yet delivered to customers will be retrofitted at BRP’s facilities before shipment.
Previous Can-Am Origin Recall
This marks the second NHTSA recall for the Can-Am Origin in its first model year. In May 2025, BRP recalled 474 Origin and Pulse electric motorcycles (NHTSA Campaign 25V275) after an improperly sealing breather valve was found to allow moisture into the high-voltage battery, posing risks of power loss or fire.
The Origin is powered by a Rotax E-Power drivetrain producing 47 horsepower and 53 lb-ft of torque from an 8.9-kWh battery. It is among a small but growing number of electric motorcycles now subject to brake-related recalls, a category that has also included Zero Motorcycles models recalled for front brake hose defects and a KTM group recall over front brake caliper casting flaws.
Owners with questions may contact BRP customer service at 1-888-272-9222 or visit the NHTSA Vehicle Safety Hotline at 1-888-327-4236.
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