Mr. Bingham’s 2017 RZR, which caught fire in Idaho in May, had received the prescribed repair after the 2018 recall, a search for his vehicle identification number on the Polaris website shows. Mr. Bingham is among the plaintiffs suing Polaris; in a response to his complaint, the company denied that his vehicle was defective.

In addition, at least three consumer complaints to the safety agency cite RZR fires after the regulatory settlement, including two involving 2018 and 2019 models.

The safety agency said in an email that as part of the 2018 penalty, Polaris had committed to imposing “an enhanced compliance program” and a “system of internal controls and procedures designed to ensure timely reporting in the future.”

The commission also said it was working with three industry groups to develop a voluntary standard that addressed “the thermal and debris penetration hazards that we have seen with on- and off-road vehicles industrywide.” The agency is barred from introducing regulations if an adequate voluntary standard exists.

In a statement for this article, Polaris cited ways in which it had “invested in safety and quality over the last several years,” affecting its product development and its processes for identifying and responding to quality and safety issues.

For many customers, any danger is overshadowed by excitement. Even though Mr. Almanza has seen more RZRs catch fire, he looks forward to Camp RZR each year. “They do the big giveaways,” he said. “And they’re really big on fixing vehicles for free at that event.”

But in case a fire does occur, he practices getting out of his four-seat RZR quickly with his wife, 2-year-old son and 14-year-old sister. “It’s just a mentality now,” he said. “If a fire happens, we are kind of prepared.”