T-16-04

T-16-04
2015-2017
November 30, 2016
November 30, 2017
VERSION: R01 (November 30, 2016)
SUBJECT
2015-2017 Slingshot Steering Shaft Pinch Bolt and Set Screw Replacement
PURPOSE
Polaris has determined that some Slingshot vehicles could have a steering shaft pinch bolt and set screw that do not meet
Polaris quality standards. To improve the steering shaft fit and reduce steering wheel free-play, Polaris has completed
validation of revised steering shaft hardware.
Refer to “Unit Inquiry” on the dealer website to ensure each vehicle is within the specified VIN range for this Service
Bulletin. Refer to the repair procedure below for the proper steps to complete this bulletin.
Your service department MUST perform the following actions as directed by this Service Bulletin:
1. Each member of your service department team must review this Service Bulletin in its entirety.
2. Each member of your service department team must watch the training video prior to ordering ANY parts,
completing ANY work, or submitting ANY warranty claim for this Service Bulletin.
AFFECTED MODELS
MODEL YEAR
2015
MODELS
Slingshot
T15AASFAAC / BC / CC
Slingshot SL
T15AAPFAAB / BB / CB
Slingshot LE
Slingshot
2016
Slingshot SL
Slingshot LE
Slingshot
2017
MODEL NUMBERS
Slingshot SL
Slingshot SLR
VEHICLE IDENTIFICATION NUMBER
RANGE
T15AAPFAAD / BD / CD
T16AASFAAA / AC / BA / BC /
CA / CC
T16AAPFAAB / AH / AJ / BB / BH
/ BJ / CB / CH / CJ / EB / EH / EJ
T16AAPFAAF / AG / AK / BF / BG
/ BK / CF / CG / CK / EF / EG /
EK
Reference “Unit Inquiry” on the dealer website
or the Service Bulletin list on the STOP site to
lookup affected units.
T17AASFAAA / BA / CA
T17AAPFAAF / AL / BF / BL / CF
/ CL
T17AARFAAE / AM / BE / BM /
CE / CM
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 1 of 16)
CUSTOMER NOTIFICATION
Dealers are required to review their sales records and make arrangements with customers as needed. In addition to
consumer units, dealers are required to correct any affected units in their inventory.
WARRANTY CLAIM / PARTS INFORMATION
A single group claim may be submitted listing the complete (17-digit) Vehicle Identification Number for machines with the
same model number. File claim type SB (Service Bulletin). Do NOT put more than one model number on a claim.
SERVICE BULLETIN #
T-16-04
CLAIM TYPE
SB (Service Bulletin)
LABOR ALLOWANCE
0.6 hrs (36 minutes)
PART NUMBER / DESCRIPTION
2207074 (QTY 1) K-SLG, STEERING
7170107 (QTY 1) BULLETIN COMPLETION DECAL
PARTS AVAILABILITY
Available to order
UNIVERSITY OF POLARIS VIDEO
TRAINING REQUIREMENT
YES*
*Polaris requires 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.
NOTE
Polaris requires dealers to maintain warranty records, including repair orders and supporting documentation for five
years. All claims for additional labor, dealer transport/travel or part stock claims for T-16-04 are subject to audit and
inspection. Infractions will result in chargebacks and fines in accordance with the Polaris Audit Policy.
WARRANTY COVERAGE PERIOD
Warranty coverage for Service Bulletin T-16-04 will begin November 30, 2016. This bulletin expires November 30, 2017.
DISPOSAL INFORMATION
Under no circumstances shall the parts removed in this repair be re-used, sold, or re-purposed for another application. It
is your dealership / distributor’s responsibility to make sure every part replaced (related to this bulletin) is taken out of
circulation and disposed of properly.
SERVICE BULLETIN COMPLETION DECAL
A Service Bulletin Completion Decal must be completed for this bulletin repair. Remove the hood and place the decal on
an easily visible portion of vehicle. If you require more decals, order them through normal Polaris parts ordering channels.
Sincerely,
Doug Koch
Technical Service and Warranty Manager
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 2 of 16)
IMPORTANT
Several steps of this procedure require an audit by another dealership representative other than the
technician who is completing the repair. Completing these check backs is a critical component to
ensuring the repair has been properly completed.
An audit checklist will be provided with each kit. It must be completed and retained with the instruction
sign-off and repair order.
AUDIT CHECKLIST:
 Verify that the Alignment Sleeve is properly installed and mark with a paint pen.
 Verify that the Retaining Nut has been torqued using a torque wrench set to the correct specification and mark with a paint
pen. Torque value: 32 ft-lbs (43 Nm)
 Verify that the Check Gauge DOES NOT insert between the EPAS housing machined face and the face of the Steering
Yoke. Mark with a paint pen.
 Verify a solid connection of the Intake Hose, Breather Hose and Air Temp Sensor. Verify the air temp sensor line is routed
properly and the Intake Hose Clamps were torqued using a torque wrench set to the correct specification. Mark hose
clamps and breather hose clamp with a paint pen. Torque value: 35 in-lbs (4 Nm)
 Verify that the Jam Nut has been torqued using a torque wrench set to the correct specification and mark with a paint pen.
Torque value: 60 in-lbs (7 Nm)
 Verify that the Steering Wheel has no free play and mark steering shaft joint with a paint pen.
 Verify that the Negative Cable Eyelet Nut has been torqued using a torque wrench set to the correct specification and mark
with a paint pen. Torque value: 60 in-lbs (7 Nm)
 Verify that the EPAS Warning Lamp is not illuminated when the key is turned to the “ON” position.
UNIVERSITY OF POLARIS VIDEO TRAINING REQUIREMENT
Each member of your service department team must watch the training video on University of Polaris prior to completing
any work, or submitting ANY warranty claim for this Service Bulletin. You must watch the video through the University of
Polaris in order to get credit for watching the video.
www.universityofpolaris.com
FEEDBACK FORM
A feedback form has been created for the technician to provide POLARIS with an overall
satisfaction rating for the instructions, provide comments on your experience or upload
pictures/videos from a specific repair. This feedback form is viewable on a mobile device by
scanning the QR code shown or by clicking HERE if viewing this document electronically.
FEEDBACK FORM
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 3 of 16)
KIT CONTENTS (P/N 2207074)
REF
①
②
③
④
⑤
PART DESCRIPTION
BOLT
NUT
SET SCREW
ALIGNMENT SLEEVE
NO-GO CHECK GAUGE
PART NUMBER
7520722
7547039
7520517
5454206
5141363
QTY
1
1
1
1
1
INSTRUCTIONS (not shown)
9927911
1
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 4 of 16)
2207074 - PART PROCEDURE
STEERING SHAFT PARTS REPLACEMENT PROCEDURE
Tools Required:
•
•
•
•
•
4mm Allen Wrench
8mm, 10mm, 13mm, 15mm Socket
Ratcheting Wrench
Torque Wrench
Short extension
•
•
•
•
15 mm open end wrench
17 mm open end wrench
T40 Torx Bit & Driver
Multi-function Pliers
REMOVAL
1. Park vehicle on a flat and level surface. Keep transmission in
gear. Engage parking brake. Turn key to “OFF” position and
remove from vehicle.
2. Remove the driver’s side lower close out panel ① by
removing the push rivets ② and T40 fasteners ③.
Loosen and disconnect negative battery cable.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 5 of 16)
3. Access the jam nut from the footwell area on the driver’s
side. Remove the jam nut ④ from the steering shaft
collar.
4. Remove set screw ⑤ and DISCARD.
5. Open vehicle hood.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 6 of 16)
6. Base and SL Models
Loosen two hose clamps ⑥, Disconnect Air Temp
Sensor ⑦ and Breather Hose ⑧. Remove Intake Hose
to allow access to the Steering Shaft Pinch Bolt.
SLR Models
Loosen hose clamp ⑥, Disconnect Air Temp Sensor ⑦
and Breather Hose ⑧. Remove the fastener retaining
the Intake Tube to the frame and the nut retaining the Air
Filter to the frame. Remove Intake assembly to allow
access to the Steering Shaft Pinch Bolt.
7. Cover Intake ⑨ to prevent debris from entering the
engine.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 7 of 16)
8. Position the steering wheel to align the wheels facing
straight forward. Locate the steering shaft and pinch bolt
from the driver side of the vehicle.
NOTE
For ease of access, orient the pinch bolt on top of
steering shaft horizontally; adjust the steering wheel as
needed.
IMPORTANT
Use a paint pen to mark clocking of the steering shaft to
the EPAS shaft for reassembly.
9. Disconnect EPAS electrical connector ⑩.
10. Remove the Pinch Bolt ⑪ and Nut ⑫ from the Steering
Shaft and DISCARD.
CAUTION
Use care when loosening and removing Pinch Bolt and
Retaining Nut to avoid damaging the brake lines.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 8 of 16)
11. Slide Steering Shaft yoke up and off the EPAS shaft.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 9 of 16)
INSTALLATION
1. Install alignment sleeve onto EPAS shaft until sleeve stop
contacts the end of the EPAS shaft as shown.
2. Align steering shaft yoke to alignment sleeve and install
steering shaft yoke onto EPAS shaft until bottomed
against alignment sleeve.
NOTE
Align yoke to paint mark to ensure correct steering wheel
clock orientation.
3. Install new Pinch Bolt ⑫ and Retaining
Nut ⑬. Torque Retaining Nut to specification.
TORQUE
Retaining Nut:
32 ft-lbs (43 Nm)
CAUTION
Bolt should install freely when properly aligned to the bolt
retention groove in the EPAS shaft. DO NOT force bolt
into the yoke.
Use care when tightening Retaining Nut to avoid
damaging the brake lines.
IMPORTANT – AUDIT STEP
A secondary dealer representative must verify that the
alignment sleeve is properly installed. Mark the alignment
sleeve with a paint pen.
IMPORTANT – AUDIT STEP
A secondary dealer representative must verify that the
Retaining Nut was torqued using a torque wrench set to
the correct specification. Mark the nut with a paint pen to
indicate the audit has been completed.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 10 of 16)
4. To verify that the steering shaft is in proper alignment,
attempt to insert the NO-GO Check Gauge in between
the EPAS housing machined face and the face of the
Steering Yoke as shown.
IMPORTANT
• If the Check Gauge DOES NOT insert between the
EPAS housing machined face and the face of the
Steering Yoke, continue to the next step.
• If the NO-GO Check Gauge DOES insert between the
EPAS housing machined face and the face of the
Steering Yoke, remove the steering shaft and start
over at step 1 of the Installation procedure.
IMPORTANT – AUDIT STEP
A secondary dealer representative must verify that the
Check Gauge DOES NOT insert between the EPAS
housing machined face and the face of the Steering
Yoke. Mark the Steering Yoke with a paint pen to indicate
the audit has been completed.
5. Turn steering wheel to point to wheels straight forward.
Confirm that the steering wheel is correctly aligned to
match the wheels.
NOTE
If the steering wheel and wheels are not properly aligned,
return to step 2 of the installation procedure to properly
align shaft markings.
6. Connect EPAS electrical connector ⑪.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 11 of 16)
7. Uncover the engine intake ⑩.
8. Base and SL Models
Reinstall Intake Hose. Connect two hose clamps ⑨, and
breather hose ⑧. Torque hose clamps to specification.
TORQUE
Intake Hose Clamps:
35 in-lbs (4 Nm)
SLR Models
Reinstall Intake assembly. Connect hose clamp ⑨, and
breather hose ⑧. Install the fastener retaining the Intake
Tube to the frame and the nut retaining the Air Filter to
the frame. Torque hose clamp, nut, and fastener to
specification.
TORQUE
Intake Hose Clamp:
35 in-lbs (4 Nm)
Air Filter Nut:
40 in-lbs (4 Nm)
Intake Tube Fastener:
8 ft-lbs (11 Nm)
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 12 of 16)
9. Connect air temp sensor ⑦.
NOTE
Make sure the air temp sensor is properly routed as
shown and is properly secured ⑥.
IMPORTANT – AUDIT STEP
A secondary dealer representative must verify a solid
connection of the Intake Hose, Breather Hose and Air
Temp Sensor. Verify the air temp sensor line is routed
properly and the Intake Hose Clamps have been torqued
using a torque wrench set to the correct specification.
Mark hose clamps and breather hose clamp with a paint
pen to indicate the audit has been completed.
Base and SL Models
SLR Models
10. Loosely install new Set Screw ⑤.
NOTE
Rotate steering wheel to allow access to install Set
Screw and Retaining Nut as required.
IMPORTANT
Flat Nosed Design
Tapered Design
Make sure the NEW Tapered Design set screw is being
installed.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 13 of 16)
11. Have an assistant slightly move the steering wheel back
and forth. Place one hand on the joint where the inner
and outer steering shafts meet to feel for free play.
Continue to tighten the set screw until the free play
between the inner and outer steering shafts is gone.
NOTE
This step will require the help of an assistant.
12. Tighten the set screw an additional 20°.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 14 of 16)
13. Reinstall jam nut ④ and torque to specification.
TORQUE
Steering Shaft Jam Nut:
60 in-lbs (7 Nm)
IMPORTANT – AUDIT STEP
A secondary dealer representative must verify that the
Jam Nut has been torqued using a torque wrench set to
the correct specification. Mark the jam nut with a paint
pen to indicate the audit has been completed.
14. Confirm that no free play is felt at the steering wheel.
IMPORTANT – AUDIT STEP
A secondary dealer representative must confirm the
steering wheel has no free play. Mark the steering shaft
joint with a paint pen to indicate the audit has been
completed.
15. Turn steering wheel full lock counter clockwise and
clockwise to confirm a full range of travel.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 15 of 16)
16. Connect ground (negative) cable eyelet to chassis stud.
Torque to specification.
TORQUE
Negative Cable Eyelet Nut:
60 in-lbs (7 Nm)
IMPORTANT – AUDIT STEP
A secondary dealer representative must confirm that the
Negative Cable Eyelet Nut has been torqued using a
torque wrench set to the correct specification. Mark the
Nut with a paint pen to indicate the audit has been
completed.
17. Install the driver’s side lower close out panel ① by
installing the push rivets ② and T40 fasteners ③.
Torque fasteners to specification.
TORQUE
Rear Body Panel Fasteners:
36 in-lbs (4 Nm)
18. Turn the key to “ON” position and allow gauges to power
up (wait 1 second after key ON). Look at the Tachometer
display and confirm that the EPAS Warning Lamp symbol
is NOT illuminated.
IMPORTANT – AUDIT STEP
A secondary dealer representative must confirm that the
EPAS Warning Lamp is not illuminated when the key is
turned to the “ON” position.
19. Install a completed Service Bulletin Completion Decal
(7170107). Close the vehicle’s hood.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Ind. This Service Bulletin is provided for the sole use of
authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2016 Polaris Ind. (Page 16 of 16)