A fire-hazard defect in more than 245,000 Ryobi 40V cordless mowers has triggered the year’s most significant outdoor power equipment recall. For owners of affected units, the repair path is straightforward — TTI offers free replacements — but the incident raises wider questions about battery safety in cordless lawn tools. Here is what you need to know about the affected models, the recall process, and whether the brand still holds up.
Manufacturer: Techtronic Industries (TTI) · Recall Units: 245,900+ (US + Canada) · Announced: February 6, 2025
Quick snapshot
- 245,900+ units recalled in US and Canada (CPSC)
- 97 overheating reports, 5 fires, 2 minor burns (CPSC)
- Defect traced to push-on connector in powerhead (Pro Tool Reviews)
- Whether European or Australian units fall under the same recall
- Whether replacement mowers carry the same redesigned connector
- Long-term user satisfaction data on recalled models replaced post-notice
- Owners must cut the power line and contact TTI for a free replacement
- Free call: 800-597-9624 (9am–5pm ET) or ryobitools.com/support/safety
- Replacement mowers reportedly dispatched as brand-new units
| Specification | Detail |
|---|---|
| Power Source | Cordless battery (40V HP models common) |
| Recall Status | Active — CPSC Recall #25-127 |
| Brand Owner | Techtronic Industries (TTI) |
| US Affected Units | 217,500 (CPSC) |
| Canada Affected Units | 28,400 (Health Canada) |
| Common Voltage | 40V HP Brushless |
| Cutting Width | 33cm (example model) |
| Retail Price Range | $500–$700 before recall |
What are the common problems with Ryobi lawn mowers?
User reviews and support forum posts surface two recurring problem categories with Ryobi cordless mowers: startup reliability and battery performance. Owners frequently report that mowers fail to start after extended storage, a symptom often traced to deeply discharged batteries left connected over winter. Battery drain during a single mowing session also appears in complaints, particularly for yards exceeding a quarter acre on 40V models.
The recall issue sits on a different tier. Beyond routine battery complaints, the US Consumer Product Safety Commission (CPSC) confirmed that Ryobi received 97 reports of overheating in the recalled models, including 5 fires and 2 minor burn injuries (CPSC). The root cause is a push-on connector inside the powerhead that can overheat during use, posing a fire hazard.
Repair and troubleshooting tips
- Remove the battery after every use — Ryobi does not recommend leaving the battery installed during storage
- If the mower fails to start, check the battery charge level before assuming a mechanical fault
- Clean the underdeck regularly; grass buildup can strain the motor and mimic battery failure symptoms
- For recalled models, do not attempt repair — contact TTI directly for a free replacement
Battery and motor issues
Ryobi’s ONE+ battery system means the 40V battery that powers the mower also works with a wide range of other Ryobi tools, which users generally praise for cross-compatibility. However, that same shared-battery design means battery degradation across tools compounds over time. A battery that no longer holds charge through a full mowing session is a common complaint outside the recall context (Victimaid).
Is the Ryobi lawn mower any good?
Ryobi positions its cordless mowers as the convenient middle ground between cheap petrol machines and premium electric models. The brand targets homeowners who want enough power for regular lawn maintenance without the noise, pull-start frustration, or emissions of gas engines. On paper, the Ryobi 40V HP Brushless 21″ model delivers a 21-inch cutting deck and brushless motor designed for longer runtime and quieter operation than brushed-motor competitors.
The reputation, however, carries a split personality. Independent tool sites generally give Ryobi cordless mowers solid marks for ease of assembly, lightweight handling, and ONE+ ecosystem value — the same battery and charger working across dozens of power tools is a genuine convenience for homeowners who already own Ryobi drills or blowers. SlashGear notes that the mower recall falls among Ryobi’s more significant recent quality events, though the brand’s overall catalog remains broadly trusted for light-to-moderate yard work (SlashGear).
Long-term review insights
Long-term owners report that build quality holds up reasonably well for suburban lawn use, with most failures occurring in the battery or charger rather than the mower deck itself. Ryobi backs mowers with a three-year warranty, which compares favorably to some competitors at similar price points.
Performance in real gardens
- Effective on residential lawns up to a quarter acre per charge on 40V HP models
- Handles standard grass types without bogging; thick or wet grass reduces runtime significantly
- Foldable handle and lightweight frame score high marks for storage in smaller garages
Ryobi mowers work well for the right user — a homeowner with a medium-sized suburban lawn who values quiet operation and already invests in the ONE+ ecosystem. For yards pushing half an acre or more, or for anyone who views lawn mowing as a serious long-term investment, the recall introduces a legitimate reason to reconsider.
How long does a Ryobi lawn mower last?
Ryobi does not publish an official lifespan figure for its cordless mowers, which is standard for consumer-grade outdoor power equipment. Industry consensus among tool sources places the expected service life at five to seven years under regular residential use, with battery capacity typically declining after three to four years of regular cycling.
The recall complicates that timeline for affected owners. Units sold between January 2021 and January 2025 are now subject to mandatory replacement, which means for those 245,900+ mowers, “lifespan” is being cut short by a safety defect rather than wear-and-tear. Replacement mowers reportedly ship as brand-new units, giving affected owners a fresh start — though the long-term reliability of replacement units remains unverified (YouTube Review).
Overall lifespan factors
- Battery age and cycling frequency — more cycles mean faster degradation
- Storage conditions — wet or extreme cold accelerates battery and motor wear
- Cutting frequency and grass type — heavy weekly cuts through thick grass stress the motor
- Maintenance habits — regular blade sharpening and underdeck cleaning extend usable life
Battery charge duration
Real-world user reports for the 40V HP model suggest 45 to 60 minutes of runtime on a fully charged battery under standard conditions, which translates roughly to a quarter-acre residential lawn. Runtime drops noticeably in thick, damp grass or when the cutting height is set low. Extended runtime typically requires a second charged battery — a purchase many owners make as a matter of course through the ONE+ system.
If your Ryobi mower is among the recalled models, lifespan projections are secondary to the recall action: stop using it, disable it by cutting the main power line, and contact TTI before the mower sits idle for another season.
Why are Ryobi mowers being recalled?
Ryobi mowers are being recalled because a push-on connector inside the powerhead can overheat during operation, creating a fire hazard. The defect affects specific 40-volt brushless models sold across the United States and Canada. The announcement came from the CPSC on February 6, 2025, under recall number 25-127, following 97 incident reports from consumers (CPSC).
The scale is significant. About 217,500 units in the US and 28,400 in Canada fall under the recall, sold primarily through Home Depot and the Direct Tools Factory Outlet from January 2021 through January 2025. In the US, the overheating issue escalated to five confirmed fires and two minor burn injuries. In Canada, Health Canada reported one fire with no injuries as of January 24, 2025 (Health Canada).
Recall details from TTI
Ryobi’s parent company, Techtronic Industries (TTI), is offering free replacement mowers to all registered owners of affected units. The replacement process requires owners to render the recalled mower inoperable — specifically, by cutting the main power line — and then contacting TTI with photos of the cut power line, serial number, and model number for verification (Pro Tool Reviews).
- TTI recall hotline: 800-597-9624 (9am–5pm ET)
- Online portal: ryobitools.com/support/safety
- Affected models include RY401014BTLUS, RY401014US, RY401140US, RY401015BTLUS, RY401015US, RY401150US, RY401140US-Y, RY401150US-Y, RY401020, RY401200, and Canadian extras RY401160US, RY401016US
- Serial number range: KC21032D010001 to KC21327N999999
Affected models and safety risks
The recalled mowers feature a black cutting deck with gray top housing and a black grass bag stamped with “RYOBI.” Model and serial numbers are located inside the green mower housing. TTI’s official recall page also prompts users to check whether their mower deck is green or gray, as the gray-deck models are eligible for the replacement program (RYOBI Tools).
The safety risk extends beyond overheating. Some users have reportedly experienced mowers starting on their own without the key inserted, adding an additional hazard beyond the fire risk cited in the official recall notice (YouTube Review).
The recall notice has not been universally communicated. Many owners reportedly learned about the mower recall only after a separate RYOBI pressure washer recall in August 2025 — involving over 700,000 units — triggered broader media attention to the brand’s safety record. If you bought a Ryobi cordless mower between 2021 and early 2025, check your model number now.
Is it okay to leave the battery in a Ryobi lawn mower?
Ryobi advises against leaving the battery installed in the mower during storage. The recommendation applies to all ONE+ 40V models, not just those under recall. Leaving a battery connected during extended storage — particularly over winter — accelerates self-discharge and can push the cells into a deep-discharge state that permanently reduces capacity or triggers protective circuitry that prevents charging.
For recalled models, the battery storage question carries additional weight. Beyond routine battery health, removing the battery eliminates one potential ignition source if the mower’s powerhead is stored near flammable materials. Owners who have received replacement mowers report that the new units include updated storage guidance as part of the replacement documentation (YouTube Review).
Storage best practices
- Remove the battery after each use and store it separately in a cool, dry location
- Store the battery at approximately 40–60% charge if keeping it idle for more than a few weeks
- Avoid leaving the mower in direct sunlight or in freezing temperatures with the battery installed
- Check battery charge level before the first spring mowing — recharge if below 20%
Risks of leaving battery installed
Beyond the fire-hazard recall, the routine risk of leaving a battery installed centers on deep discharge. Lithium-ion batteries have a self-discharge rate that, over weeks or months, can drain cells below the voltage threshold needed to initiate normal charging. In extreme cases, deeply discharged lithium packs can generate heat during attempted recharging. Consistent removal and periodic charging is the low-effort habit that prevents most battery-related problems in Ryobi ONE+ tools.
Upsides
- ONE+ cross-tool compatibility adds genuine value for homeowners already in the Ryobi ecosystem
- Lightweight, quiet operation compared to petrol mowers
- Free replacement program means no out-of-pocket cost for recalled model owners
- 40V HP models deliver solid runtime for medium-sized suburban lawns
Downsides
- Recall affects 245,900+ units with fire and injury incidents confirmed
- Battery degradation over 3–4 years reduces runtime for heavy users
- Replacement process requires disabling the original mower (cutting power line)
- Limited to a quarter-acre per charge on 40V models — insufficient for larger properties
Ryobi lawn mower models covered by the recall
Ten model numbers appear in the US recall notice, with two additional models exclusive to the Canadian recall. All are 40-volt brushless walk-behind mowers with model numbers beginning in the RY401x series. The models sold primarily at Home Depot and the Direct Tools Factory Outlet from early 2021 through January 2025. Serial numbers for affected units fall between KC21032D010001 and KC21327N999999.
| Model Number | Market | Notes |
|---|---|---|
| RY401014BTLUS | US | Bundle kit version |
| RY401014US | US | Standard retail |
| RY401140US | US | Standard retail |
| RY401015BTLUS | US | Bundle kit version |
| RY401015US | US | Standard retail |
| RY401150US | US | Standard retail |
| RY401140US-Y | US | Yellow variant |
| RY401150US-Y | US | Yellow variant |
| RY401020 | US | Standard retail |
| RY401200 | US | Standard retail |
| RY401160US | Canada only | Additional Canadian model |
| RY401016US | Canada only | Additional Canadian model |
The 12 models together represent the primary 40V brushless lineup sold during the recall window, though not every model number in the RY401 series is affected — models with green decks rather than black decks or units with serial numbers outside the specified range are not subject to the replacement program.
Ryobi also recalled the P108 Lithium-Ion 18V 4AH battery previously, placing the mower recall in the context of a brand with multiple battery-safety events on record. Buyers evaluating the broader Ryobi ecosystem should factor in how TTI handles warranty and recall responsiveness — an area where this replacement program, at least on paper, provides a free resolution.
The recalled mowers have a push-on connector inside the powerhead that can overheat, posing a fire hazard.
— CPSC recall notice (CPSC #25-127)
Consumers should immediately stop using the recalled mower and contact TTI for instructions on how to disable the recalled mower and receive a free replacement.
— CPSC official guidance
TTI has received 97 reports of overheating while the mower was in use, including five reports of fires. Two minor burn injuries have been reported.
— CPSC incident summary
Ryobi’s core value proposition — a battery-powered mower that is quiet, lightweight, and integrated into one of the most expansive cordless tool ecosystems on the market — remains intact for models outside the recall. The 40V HP Brushless line continues to receive generally positive marks for regular suburban use, and the free replacement program removes the financial sting for owners of affected units.
For UK and Ireland buyers, the situation differs materially. The recall as documented applies to units sold in the US and Canada; official notices from RYOBI UK and European distributors were not identified in the available regulatory records. Buyers in those regions importing or purchasing through grey-market channels should verify model eligibility directly with RYOBI support before assuming their unit is unaffected. The grey imported units may fall outside warranty coverage even if they share the same model numbers.
The broader pattern for existing owners is straightforward: check your model number, act immediately if your mower is on the recall list, and adopt battery storage habits that reduce fire risk regardless of your mower’s recall status. For prospective buyers, the calculus has shifted: a recalled product with a free replacement resolution is less alarming than it might otherwise be, but the incident reports — 97 overheating cases, 5 fires — are a reminder that battery-powered outdoor equipment carries risks that petrol mowers do not, and that brand trust rests on how manufacturers respond when those risks materialize.
For anyone deciding whether to buy a Ryobi mower today, the question is not whether the brand is trustworthy in general — it is whether the current production models have resolved the connector issue that caused the recall, and whether TTI’s replacement process is responsive enough to turn a serious safety problem into a resolved one. As of early 2025, the replacement program is active and the recall is ongoing.
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Frequently asked questions
What models are affected by Ryobi mower recalls?
Ten models are covered in the US: RY401014BTLUS, RY401014US, RY401140US, RY401015BTLUS, RY401015US, RY401150US, RY401140US-Y, RY401150US-Y, RY401020, and RY401200. Canada adds RY401160US and RY401016US. Serial numbers must fall between KC21032D010001 and KC21327N999999 to qualify.
How do you troubleshoot a Ryobi lawn mower that won’t start?
Check the battery charge first — remove the battery and test it in another ONE+ tool or with a multimeter. If the battery shows charge, clean the underdeck and check that the blade is not locked. For recalled models, stop troubleshooting and contact TTI: the mower is subject to a mandatory replacement, not a repair.
Are Ryobi lawn mowers compatible with other Ryobi batteries?
Yes — the ONE+ system means any 40V Ryobi battery works in any 40V Ryobi tool, including mowers, blowers, trimmers, and saws. This cross-compatibility is one of the strongest features of the Ryobi ecosystem and means a second battery purchases once works across multiple machines.
Where can I buy Ryobi lawn mowers in Ireland?
Ryobi products in Ireland are primarily available through retailers including Screwfix Ireland, Woodie’s, and online marketplaces. Check local stock availability for 40V models, noting that the recall applies to US and Canadian units — Irish warranty terms may differ for grey-market imports.
What is the warranty on Ryobi lawn mowers?
Ryobi mowers typically carry a three-year warranty covering manufacturing defects. The warranty does not cover battery degradation over normal use, and recalled models are handled under the separate free replacement program rather than the standard warranty process.
Do Ryobi lawn mowers work on thick grass?
They handle standard residential grass conditions adequately. In thick or tall grass, runtime drops noticeably and the mower may strain or stall on the lowest cutting heights. For properties with heavy, damp, or overgrown grass, a petrol mower or a higher-output cordless model is a better fit.
How to clean a Ryobi lawn mower?
Remove the battery, tip the mower on its side (air filter up), and use a garden hose to flush the underdeck clear of clippings. Avoid pressure washers, which can force water into the motor housing. Dry the underdeck and reinstall the blade before storage. Clean after every four to five uses for optimal motor life.
How long does the recall replacement take?
TTI reportedly ships replacement mowers as new units after verifying the cut power line, serial number, and model number photos. Actual delivery timelines vary by region and current processing volume; reported experiences range from several weeks to a few months from submission to receipt.
Andrew Ellis leads fact-checking, source verification and corrections at Australia Focus.