TSA-18-02

On-Road
TSA-18-02
April 26, 2018
EXPIRATION DATE: December 31, 2020
VERSION: R01 (April 26, 2018)
SUBJECT:
2015-17 Slingshot – Brake Pressure Switch Replacement
PURPOSE:
Polaris has identified a quality issue affecting some Slingshot brake pressure switches. An intermittent failure of the switch
triggers a “Brake Failure” malfunction indicator lamp, which is visible on the gauge cluster. There is no change in brake
function as a result of this failure.
This Service Advisory has been released to communicate a process which enables dealers to assist customers and
replace affected brake pressure switches 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 brake pressure switches 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 - 2017
Models
Affected Model range
Slingshot
All models manufactured before
11/1/2016. 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 the issue outlined in this Service Advisory, proceed to the following
steps. This Service Advisory is not a required update. This Service Advisory provides goodwill parts and labor coverage
until December 31, 2020 on vehicles exhibiting the issue as defined in this Service Advisory. If a customer alerts the
dealership about symptoms relating to a defective brake pressure switch, follow the repair procedure in this Service
Advisory.
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:
2015-17 Slingshot / Slingshot SL / Slingshot SLR
Service Advisory #
TSA-18-02
Claim Type
SA (Service Advisory)
Labor Allowance
1.1 hours (66 minutes)
Part Number / Description
2207836 (QTY.1) – KIT, BPS REPLACE
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:
Located on the side of the brake pressure switch (4013596) is a 4 digit manufacture date code. In reference to the picture
below, the first two digits (03) represent the week of manufacture and the last two digits (16) represent the year of
manufacture. Dealers should review their service parts inventory and ensure switches dated prior to 4316 (the 43rd week
of 2016) are NOT used for any repairs. The example below is
a potentially defective switch since the date code indicates it
was manufactured on the 3rd week of 2016.
Switches dated 4316 or later (0317, 0118, etc.) can be used if
the procedure outlined below is followed and the components
specified in this procedure are used. For your convenience, a
new Brake Pressure Switch service kit (PN 2207836) has
been created for this advisory. The kit includes all parts and
materials needed to successfully perform this repair and will
represent the standard service part available on the dealer
website.
IMPORTANT
Make sure the Brake Pressure Switch has a build date of 4316 or later.
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-18-02” in the CONCERN field.
5. Enter “TSA-18-02” in the CAUSE field.
6. Enter “TSA-18-02” in the CORRECTION field.
7. Enter the part number and quantity.
8. Enter warranty fail codes: 124/412/152.
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.
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-18-02
© 2018 Polaris Industries Inc.
(Page 2 of 15)
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.
KIT CONTENTS (2207836)
REF
QTY
PART DESCRIPTION
PART NUMBER
①
4
STAT-O-SEAL
5413212
②
2
BRAKE PRESSURE SWITCH
4016380
1
LUBRICANT (not shown)
8560254
2
Shop Towel (not shown)
2830403
1
Instructions, Kit (not shown)
9929251
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-18-02
© 2018 Polaris Industries Inc.
(Page 3 of 15)
PART 1: STAT-O-SEAL REPLACEMENT
Tools Required:
•
•
•
•
•
•
•
Standard Screw Driver
T40 Torx Bit & Driver
3/8″ drive ratchet
3/8” drive wobble extension
8 mm, 13 mm, and 22 mm or 7/8” deep well sockets
(3/8” drive)
10 mm socket (3/8” drive)
Ratcheting torque wrench that can measure
down to 35 in-lbs (3/8″ drive)
•
•
•
•
•
•
10 mm box end wrench
13 mm open end wrench
Clear rubber hose ¼” inside diameter
Clean container
Multi-function Pliers
Flashlight
REMOVAL
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-18-02
© 2018 Polaris Industries Inc.
(Page 4 of 15)
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-18-02
© 2018 Polaris Industries Inc.
(Page 5 of 15)
NOTE
Access master cylinder retaining bolts through driver
footwell using a ratchet and extension or under hood
area using a 13mm open end wrench.
IMPORTANT
Be careful when moving the Master Cylinder not to
damage any brake lines, wiring, or the master cylinder
boot.
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-18-02
© 2018 Polaris Industries Inc.
(Page 6 of 15)
NOTE
Use a rag to contain the small amount of brake fluid that
may drain from the Master Cylinder and brake lines.
CAUTION
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
INSTALLATION
IMPORTANT
Make sure the Brake Pressure Switch has a build date of
4316 or later.
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-18-02
© 2018 Polaris Industries Inc.
(Page 7 of 15)
NOTE
Before tightening, make sure brake lines are properly
aligned in notches of master cylinder as shown.
CRITICAL
The Brake Pressure Switch torque is critical.
DO NOT OVERTORQUE
TORQUE
Brake Pressure Switch:
12 ft-lb (16 Nm)
IMPORTANT
Visually inspect that all Stat-O-Seals are present and
properly installed.
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-18-02
© 2018 Polaris Industries Inc.
(Page 8 of 15)
NOTE
Access master cylinder retaining bolts through driver
footwell using an extension and torque wrench.
TORQUE
Master Cylinder Fasteners:
18 ft-lbs (24 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-18-02
© 2018 Polaris Industries Inc.
(Page 9 of 15)
TORQUE
Intake Hose Clamps:
35 in-lbs (4 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-18-02
© 2018 Polaris Industries Inc.
(Page 10 of 15)
NOTE
Make sure the air temp sensor is properly routed
underneath the breather hose and coolant line as shown
and is properly secured ⑧.
TORQUE
Negative Cable Eyelet Nut:
60 in-lbs (7 Nm)
TORQUE
Rear Body Panel Fasteners:
36 in-lbs (4 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-18-02
© 2018 Polaris Industries Inc.
(Page 11 of 15)
PART 2: BRAKE BLEED PROCEDURE
CAUTION
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
NOTE
Make sure Digital Wrench is updated to version 3.8
9/14/2016 or later.
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-18-02
© 2018 Polaris Industries Inc.
(Page 12 of 15)
NOTE
You can set an Activation Delay Time (seconds) in the
white data field to allow time to prepare before activation
begins.
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-18-02
© 2018 Polaris Industries Inc.
(Page 13 of 15)
IMPORTANT
Do not release foot pedal before bleeder screw is tight or
air may be drawn into the master cylinder.
IMPORTANT
Check master cylinder fluid level after two ABS bleed
cycles on any brake circuit. Do not allow the master
cylinder to run dry during this process.
TORQUE
Bleeder Screw:
72 in-lbs (8 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-18-02
© 2018 Polaris Industries Inc.
(Page 14 of 15)
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-18-02
© 2018 Polaris Industries Inc.
(Page 15 of 15)