TSA-18-01

On-Road
TSA-18-01
February 01, 2018
EXPIRATION DATE: February 01, 2023
VERSION: R01 (February 01, 2018)
SUBJECT:
2015-18 Slingshot – Muffler noise
PURPOSE:
Polaris has identified a quality issue affecting a small number of Slingshot mufflers, where insufficient penetration of
muffler plug welds weakens the muffler wall, making it susceptible to fatigue failure. The first mode of failure is a loosening
of the wall, distinguishable by a rattle during normal engine operation. If left unrepaired for an extended period of time, a
hole may form in the muffler wall resulting in noticeably higher noise levels.
This Service Advisory has been released to communicate a process which enables dealers to assist customers and
replace affected mufflers without requiring pre-authorization from Polaris. Parts should only be replaced on vehicles
exhibiting the issue as defined in this Service Advisory. DO NOT replace mufflers proactively on units that are not
exhibiting these symptoms. Polaris reserves the right to expire this Service Advisory prior to the published
expiration date for any reason.
AFFECTED MODELS:
Model Years
2015 - 2018
Models
Affected Model range
Slingshot
All models manufactured before
9/11/2017. Manufacture date can be
found using “Unit Inquiry” on the dealer
website.
Slingshot SL
Slingshot SLR
CUSTOMER NOTIFICATION:
Dealers should not contact customers regarding this Service Advisory unless the customer has previously had this
concern. Parts should only be replaced on vehicles exhibiting the issue as defined in this Service Advisory. Polaris will not
send a letter to consumers notifying them of this Service Advisory.
WHAT YOUR DEALERSHIP SHOULD DO:
If your dealership encounters a vehicle exhibiting characteristics of a defective muffler as defined above, proceed with the
following steps:
1. Attempt to replicate the complaint to ensure the muffler is indeed the source of the noise. To replicate, run the
vehicle, sweeping from idle through the RPM range while listening for rattles, buzzing, excessive loudness, or
other abnormal exhaust sounds. The vehicle may require a load to replicate the rattle, therefore, a test drive may
be necessary.
2. If the noise is replicated, verify that the muffler is not making contact with surrounding components due to missing
or defective exhaust springs, or a loose heat shield (equipped only on select vehicles).
3. If the abnormal noise is confirmed and is the result of a defective muffler, proceed with the Muffler Replacement
Procedure on the following pages.
4. If the abnormal noise is not related to a defective muffler, proceed with the appropriate steps to diagnose and
repair.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 1 of 15)
WARRANTY CLAIM:
2015-18 Slingshot / Slingshot SL / Slingshot SLR
Service Advisory #
TSA-18-01
Claim Type
SA (Service Advisory)
Labor Allowance
0.9 hours (54 minutes)
Part Number / Description
1262781 (QTY.1) – ASM, RESONATOR, INT. CAT.
3610211 (QTY.1) – SEAL, EXHAUST, SOCKET
7043726 (QTY.6) – SPRING, EXHAUST, SS
24505057 (QTY.1) – GASKET, EXHAUST
Parts Availability
Available to order
University Of Polaris Video Training
Requirement
NO 1
1
Polaris does not require one person from a dealership to be certified before parts ordering may occur and two people from a dealership to be
certified before warranty claims may be processed.
INVENTORY / STOCK PART WARRANTY CLAIMS:
Dealers should review their service parts inventory and ensure the following service parts are NOT used for any repairs.
Located on the top of the mufflers are part number and a manufacture date code. Mufflers that have a manufacture build
date prior to 5/4/2017 should NOT be used for any repairs.
•
•
1262645 Muffler assembly
1262781 Muffler assembly (Intl.)
NOTE
To remove these service parts from circulation, file a parts
stock claim as directed below.
Please use the following process for filing PART STOCK
warranty claim for any of the parts listed above.
1. Start a new Parts Stock warranty claim.
2. Select Product Line: SLI
3. Enter the Date Failed and Date Repaired information
into the applicable fields.
4. Enter “TSA-18-01” in the CONCERN field.
5. Enter “TSA-18-01” in the CAUSE field.
6. Enter “TSA-18-01” in the CORRECTION field.
7. Enter the part number and quantity.
8. Enter warranty fail codes: 103/197/122.
9. Validate the parts.
10. Save and submit the claim to Polaris.
WARRANTY COVERAGE PERIOD:
This Service Advisory for goodwill coverage is separate from, and does not alter or otherwise affect the terms of
any existing warranty.
PARTS RETURN OR DISPOSAL INFORMATION:
Once the warranty claim for each unit has processed, please review the “Check Returned Parts List” on your dealer
website to determine whether or not Polaris has asked for the part(s) to be returned. If the part(s) were not identified as
needing to be returned to Polaris, please dispose of the part(s) properly.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 2 of 15)
MUFFLER REPLACEMENT:
CAUTION
Exhaust components may be hot. Wait for exhaust
to cool before performing service.
IMPORTANT
Do not pull on speaker wires when moving the speaker
enclosure.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 3 of 15)
NOTE
The fastener ⑥ securing the splash guard is longer than
the other four fasteners.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 4 of 15)
NOTE
Loosening the top hose clamp and rotating the shield
bracket makes muffler removal easier.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 5 of 15)
CAUTION
When removing muffler assembly, avoid damaging O2
sensor, coolant temp sensor and its wiring.
CAUTION
Avoid placing downward pressure on the coolant tank
hose. Downward pressure may result in damage to the
coolant tank barb.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 6 of 15)
NOTE
Using a pick, pry up on gasket until it releases from the
manifold. Be careful not to damage manifold pipe.
IMPORTANT
NEW exhaust socket seal is required during assembly.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 7 of 15)
NOTE
This Service Advisory authorizes the replacement of the
muffler heat shield ③ only if the heat shield is present
and shows evidence of damage at the time of inspection.
NOTE
If authorization to replace additional parts was received,
take the necessary steps to remove and replace them.
Refer to the online Slingshot service manual for details.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 8 of 15)
IMPORTANT
NEW exhaust socket seal is required during assembly.
IMPORTANT
NEW springs are required during assembly.
NOTE
The top two springs share the same flange eyelet. Make
sure the springs are secured to their proper eyelet
locations during installation.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 9 of 15)
CAUTION
When installing muffler assembly, avoid damaging O2
sensor, coolant temp sensor and its wiring.
CAUTION
Avoid placing pressure on the coolant tank hose. This
may result in damage to the coolant tank barb.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 10 of 15)
IMPORTANT
Verify exhaust manifold pipe gasket is properly installed
in downpipe before installing fasteners.
TORQUE
Downpipe Fasteners:
37 ft-lbs (50 Nm)
NOTE
Do not torque fasteners until all have been installed.
TORQUE
Heat Shield Fasteners:
36 in-lbs (4 Nm)
TORQUE
Heat Shield Clamps:
12 in-lbs (1 Nm)
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 11 of 15)
TORQUE
Exhaust Manifold Heat Shield Fasteners:
84 in-lbs (9 Nm)
IMPORTANT
Do not tighten fasteners until all have been assembled.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 12 of 15)
TORQUE
Rocker Panel Fastener:
65 in-lbs (7 Nm)
IMPORTANT
If applicable, make sure the long fastener ⑫ is used to
secure the splash guard.
TORQUE
Long Rocker Panel Fastener ⑫:
50 in-lbs (6 Nm)
TORQUE
Short Rocker Panel Fasteners ⑪:
65 in-lbs (7 Nm)
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 13 of 15)
TORQUE
Rocker Panel Fasteners:
65 in-lbs (7 Nm)
TORQUE
Rocker Panel Fasteners:
65 in-lbs (7 Nm)
TORQUE
Speaker Enclosure Fasteners:
48 in-lbs (5 Nm)
IMPORTANT
Make sure wires are not pinched between the speaker
enclosure and frame rail.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 14 of 15)
CAUTION
Exhaust components may be hot. Wait for exhaust to
cool before performing service.
TORQUE
Heat Shield Clamps:
12 in-lbs (1 Nm)
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris
Industries Inc. This document is provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed,
duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
TSA-18-01
© 2018 Polaris Industries Inc.
(Page 15 of 15)