2.579_5

Polaris Industries Inc.
Product Development Center
7290 Viking Blvd E
Wyoming, MN 55092
T: 651-408-7579
F: 651-408-7605
December 3, 2015
Associate Administrator for Enforcement
National Highway Traffic Safety Administration
1200 New Jersey Avenue, SE
Washington, D.C. 20590
RE:
579.5 Notices, bulletins, customer satisfaction campaigns, consumer advisories, and
other communications for the month of November, 2015.
Manufacturer:
Report Author:
Telephone Number:
Polaris Industries Inc. (Victory Motorcycle Division; Indian Motorcycle
Company; Global Electric Motorcars (GEM), Slingshot)
Don L. Good
651-408-7579
Polaris Industries Inc sent the following 579.5 communications in the month of November, 2015.
Copies of the above are attached to this report.
If you have any questions with this report, please contact me at 651-408-7579.
Thank you,
Signed:
Don L. Good
Sr. Product Safety Specialist
Polaris Industries Inc.
Date: 12-3-2015
Nov 5, 2015
I-15-04
2015-2016
X
IMPORTANT SAFETY NOTICE!
STOP SALE
SUBJECT: 2015-2016 Indian Full Size Motorcycles – Rear Master Cylinder Repair
PURPOSE:
Some 2015-2016 Indian Full-Size motorcycles have been manufactured with a rear brake master cylinder that does
not meet Indian Motorcycle quality standards. In some vehicles, the rear brake master cylinder piston cup may
develop a tear. Motorcycles assembled with an affected master cylinder may experience a loss of fluid pressure to
the rear brake caliper resulting in reduced rear brake performance. This could cause the vehicle operator to lose
control, increasing the risk of a crash.
AFFECTED MODELS:
2015-2016 Indian Chief Classic, Chief Vintage, Chieftain, Roadmaster, and Dark Horse Motorcycles manufactured on
or between 1/2/2015 – 10/23/2015.
Use ‘Unit Inquiry’ or the Service Bulletin VIN Lookup tool on the STOP Site to identify affected vehicles.
WHAT YOUR DEALERSHIP SHOULD DO:
Wholegood Units:
1. STOP ALL SALES of affected units until this Safety Bulletin has been completed. After the bulletin is
completed and a warranty claim has been filed, it is acceptable to resume sales.
2. Review your dealership’s inventory to locate potentially affected models.
a. Go to the STOP Site and click on the ‘Click Here for a List of Your Dealership’s Units with Open
Bulletins / Recalls’ link located in the Search Options menu.
3. Follow the instructions outlined in this Safety Bulletin to replace the affected rear master cylinder piston
assembly using the updated part detailed in this communication.
4. File a warranty claim immediately after completion of this bulletin.
Parts Stock Inventory:
1. Review your dealership’s parts stock inventory to identify any potentially affected master cylinder
assemblies:
 2205153 – KIT-ASM, REAR MC, IND
 2205751 – KIT-ASM, REAR MC, IND, BLK
 2205157 – KIT-PISTON, REAR MC, IND
2. File a Parts Stock claim for any master cylinder assemblies in dealer inventory and return to Indian
Motorcycle.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 1 of 9)
CUSTOMER NOTIFICATION:
A customer notification letter has been sent to all registered owners of motorcycles affected by this Safety Bulletin. In
addition to the notification letter sent by Indian Motorcycle, dealers are required to notify owners of motorcycles sold
by their dealership, and to make arrangements to perform this bulletin immediately.
WARRANTY CLAIM 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.
REAR MASTER CYLINDER - REBUILD
SERVICE BULLETIN #
I-15-04
CLAIM TYPE
SB (Service Bulletin)
LABOR ALLOWANCE
36 Minutes (0.6 Hours)
CLAIM PART NUMBERS
N/A – Auto Process Bulletin
PARTS INFORMATION:
REAR MASTER CYLINDER – REBUILD (I-15-04)
PART NUMBER / DESCRIPTION
PARTS AVAILABILITY
7170107 (QTY. 1) – Service Bulletin Completion Decal
2206308 (QTY. 1) – Piston Kit, Rear Master Cylinder*
7556372 (QTY. 2) – Copper Sealing Washer
7661010 (QTY. 1) – Cotter Pin, Push Rod
Available to order
*NOTE: 2206308 will be available 11/9 to order in limited quantities.
Sufficient inventory to fulfill bulletin requirements will be in stock no later
than 11/20/2015.
DIRECT-SHIP FROM POLARIS?
No
TO BE ORDERED BY DEALER?
Yes
PARTS RETURN INFORMATION:
ATTENTION: North American Dealers – All master cylinder pistons affected by this bulletin should to be returned via
the normal warranty parts return system (DO NOT RMA).
Include the Vehicle Identification Number (VIN) and the date code located on bottom of the master cylinder housing
(refer to image below). NOTE: Date code is also pin stamped on the master cylinder housing under the label.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 2 of 9)
Dealers & Distributors: Under no circumstances shall the part removed in this repair be re-used, sold, or repurposed for another application. It is your dealership / distributorship’s responsibility to make sure every part
replaced is taken out of circulation and returned to Indian Motorcycle.
For North American Dealers: 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 Indian Motorcycle has asked for the part(s)
to be returned. If the part(s) were not identified as needing to be returned to Indian Motorcycle, please dispose of
the part(s) properly.
SERVICE BULLETIN COMPLETION DECAL:
A Service Bulletin Completion Decal must be completed for this
bulletin repair. Place the decal on the unit as shown (inside left side
cover). If you require more decals, order them through normal
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 Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 3 of 9)
REAR MASTER CYLINDER PISTON REPLACEMENT:
IMPORTANT: Brake fluid and brake cleaners will damage paint, plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on the brake system. If brake fluid is spilled on cosmetic surfaces,
immediately rinse the area with a mild solution of soap and water until all traces of brake fluid are removed. Make
sure the master cylinder reservoir being worked on is level before removing the cap.
REAR MASTER CYLINDER DISASSEMBLY/INSPECTION
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the brake line banjo bolt ①. Remove
sealing washers and discard. To prevent loss of
brake fluid suspend the open end of the brake line
upright or place in a container of clean brake fluid
while servicing the master cylinder. NOTE: Prevent
brake fluid from contacting cosmetic surfaces.
3. Remove cotter pin ② from push rod pin and remove
washer.
4. Remove jam nut ③ and remove the master cylinder
from the floorboard support. NOTE: Use caution to
ensure wrench does not contact the master cylinder
reservoir.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 4 of 9)
5. Place rear brake master cylinder on a clean work
surface. IMPORTANT: Maintain cleanliness of
work surface and master cylinder components.
Any debris or fluid could damage master cylinder
components.
6. Clean rear brake master cylinder external
surfaces and remove cover screws, cover and
cover seal
7. Using a suitable fluid recovery container, pour
out the brake fluid in the master cylinder
reservoir and dispose of brake fluid properly.
8. Remove external snap ring ④, washer ⑤, dust
boot ⑥, spring retainer ⑦ and return spring ⑧.
NOTE: Spring retainer and return spring are
typically retained in the dust boot.
9. Remove and discard internal snap ring ⑨.
Remove pushrod/retainer bushing assembly ⑩
and piston assembly ⑪.
10. Remove piston return spring ⑫ from piston
assembly ⑪. NOTE: Retain and tag piston for
warranty parts return.
11. Clean all internal parts with Indian Motorcycle
DOT 4 brake fluid or isopropyl alcohol from a
sealed container.
12. Inspect cylinder bore and chamfer on front of the
bore for corrosion, scratches, scoring or pitting.
Replace master cylinder if any of these conditions
are evident.
13. Use compressed air to clear fluid holes and
passages to verify they are clean and
unobstructed.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 5 of 9)
REAR MASTER CYLINDER ASSEMBLY:
1. Insert original piston return spring ① in the NEW
piston assembly ②.
2. Lubricate piston assembly and master cylinder bore
with clean Indian Motorcycle DOT 4 brake fluid.
3. Align the piston assembly ③ with the master
cylinder bore ④.
4. Partially insert the piston assembly into the master
cylinder bore taking care so the spring does not
scratch or damage the bore. NOTE: Do not fold or
damage the piston seals and cup when inserting
piston.
5. Use a flashlight to view the spring end through the
fluid outlet port to guide the spring end into the
master cylinder counter bore (refer to image at
right).
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 6 of 9)
et
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8. Insert the pushrod ⑥ retainer bushing assembly ⑤
and depress both into master cylinder bore deep
enough until snap ring groove is visible above
retainer bushing. Install NEW snap ring ⑦ with
square edge facing out in snap ring groove. NOTE:
Verify snap ring is fully seated in groove.
r
6. Verify the spring is seated correctly in the master
cylinder counter bore before fully seating the piston
in the master cylinder bore. NOTE: Spring is
installed incorrectly if end is visible through the
outlet port (refer to image at right).
7. If spring is seated correctly proceed to step 8. If
spring is not seated correctly remove piston
assembly and repeat steps 3-7.
U
.S
.C
9. Assemble return spring ⑧, spring retainer ⑨, dust
boot (with drain hole facing down) ⑩, and washer
⑪ on the pushrod. Depress return spring, cup, dust
boot and washer down the pushrod to expose the
snap ring groove...
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 7 of 9)
10. Install the snap ring ⑫ in the pushrod groove with
the square edge facing away from master cylinder.
NOTE: Verify dust boot is seated in groove on back of
master cylinder housing
REAR MASTER CYLINDER INSTALLATION:
1. Install the master cylinder to floorboard support and
torque the jam nut ① to specification.
TORQUE:
Master Cylinder Jam Nut: 35 ft-lbs (47.5 Nm)
2. Install a NEW sealing washer ② on each side of the
banjo fitting and torque the banjo bolt ③ to
specification. NOTE: Do not reuse brake sealing
washers.
TORQUE:
Brake Line Banjo Bolt: 18 ft-lbs (24.4 Nm)
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 8 of 9)
3. Assemble the pushrod onto the brake pedal pin.
Install washer ④ and a NEW cotter pin ⑤.
4. Bleed the rear brake system as outlined in Chapter
14 of the 2014-2016 Indian Motorcycle (Full-Size)
Service Manual (PN 9925933).
5. Top up the brake fluid as necessary and install the
reservoir cover. Torque screws ⑥ to specification.
TORQUE:
M/C Reservoir Cover Screws: 13 in-lbs (1.5 Nm)
6. Test ride the motorcycle to verify proper brake
operation and pedal feel.
7. Include the VIN and master cylinder date code on a
tag attached to the original master cylinder piston for
warranty return (refer to PARTS RETURN
INFORMATION).
8. File a warranty claim for I-15-04.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 9 of 9)
IMPORTANT SAFETY RECALL
Indian Motorcycle Company
P.O. Box 47700
Medina, MN 55340-9960
This notice applies to your vehicle
VIN:
Recall Campaign: 15V-721
Subject: 2015-2016 Indian Full Size Motorcycles
Rear Master Cylinder Repair
PLEASE READ IMMEDIATELY
Dear Indian Motorcycle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Indian Motorcycle
has decided that a defect which relates to motor vehicle safety exists in certain 2015-2016 Indian Full Size motorcycles. Our records
indicate that you have purchased a potentially affected vehicle.
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The reason for this recall:
Indian Motorcycle has decided that some 2015-2016 Indian Full Size motorcycles may have been manufactured with a rear brake
master cylinder that does not meet Indian Motorcycle quality standards. In some vehicles, the primary cup seal located in the rear master
cylinder may not fully seal into the master cylinder bore. Motorcycles assembled with an affected master cylinder may experience a loss of
pressure to the rear brake caliper resulting in rear brake failure. This could cause the vehicle operator to lose control, increasing the risk
of a vehicle crash.
er
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What Indian Motorcycle and your dealer will do:
Indian Motorcycle will issue a Safety Recall Bulletin to all Indian Motorcycle dealers, with instructions required to replace the rear brake
master cylinder piston and seals. Repairs will be made by any authorized Indian Motorcycle dealer at no cost to you. The actual master
cylinder repair should take about one hour to perform; however, it may take longer due to service scheduling requirements.
What you should do:
Contact your authorized Indian Motorcycle dealer to schedule an appointment to have the bulletin repair performed. Do not attempt
repairs yourself. Repairs must be done only by an authorized Indian Motorcycle dealer.
2.
Press downward on the rear brake pedal. It should move freely and smoothly. The pedal should feel firm and continue to feel
firm until released.
Release the pedal. It should return to its rest position quickly when released.
on
1.
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Pre-Ride Inspection
Before riding your motorcycle to an authorized dealer to have the bulletin procedure(s) completed, please perform the following pre-ride
brake inspection prior to riding your motorcycle to the dealership:
.C
If the rear brake pedal fails to perform as stated or travels too far before beginning to engage the brake do not ride your motorcycle
before the repairs are made. Work with your Indian Motorcycle dealer to arrange transportation.
U
.S
If you have questions or if you need more information:
While your Indian Motorcycle dealer is in the best position to answer your questions, if you have any questions that your dealer cannot
address, if you are having difficulty obtaining the recall repair outlined in this letter, or if you need assistance finding an Indian
Motorcycle dealer, please visit the web site at www.indianmotorcycle.com or contact our Indian Motorcycle Consumer Service
Department by calling 1-877-204-3697.
This notice was mailed to you according to our most current registration information. If you no longer own your Indian motorcycle,
please contact your local Indian Motorcycle dealer to have the ownership information changed. The Indian Motorcycle Consumer
Service Department cannot change ownership information without identification. Federal law requires that any vehicle lessor receiving
this recall notice must forward a copy of this notice to the lessee within 10 days.
If you have had this repair performed before you received this letter, you may be eligible to receive reimbursement for the cost of
obtaining a pre-notification remedy of the problem associated with this recall. For more information regarding obtaining reimbursement
please contact the Indian Motorcycle Consumer Service Department using the contact information above.
If you believe that Indian Motorcycle has failed to remedy this defect without charge or is unable to do so within a reasonable time, you
may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE.,
Washington, D.C. 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1- 800-424-9153); or on the web go to
http://www.safercar.gov.
Please accept our apologies for any inconvenience this may cause you. Your safety and continued satisfaction with your Indian
Motorcycle is our primary concern. Thank you for your prompt attention to this matter.
Sincerely,
Indian Motorcycle Company
SLI-15-11-01
Nov 19, 2015
SUBJECT: SLINGSHOT – REAR SPROCKET RETAINING NUT RUNNING CHANGE
MODELS: ALL 2015-2016 SLINGSHOT MODELS
The Slingshot Division of Polaris Industries has developed updated rear sprocket retaining nuts and Loctite® on 2016
Slingshot models manufactured after 11/02/2015. The single hex flanged-style nut has been replaced with two hex head
nuts. Loctite® 641 (Yellow) applied to the rear axle splines and threads has been replaced by Loctite® 680 (Green).
Updated rear sprocket retaining nuts and Loctite® should be installed on any vehicles built prior to 11/2/2015 if any of
the following conditions are encountered:
1. A clicking or popping noise from the rear axle area during low speed operation
NOTE: This noise is similar to and may be mistaken for a damaged rear wheel bearing
2. Reduced clamp force on the rear sprocket nut
3. A service procedure requiring removal of the rear sprocket is performed
The Driven Sprocket Replacement procedure in the Slingshot Service Manual has been updated and posted on the
STOP Site for reference, update your manual accordingly. The Polaris Online Electronic Parts Catalog has also been
updated to include the new hardware.
OLD (PN 7547617 – QTY 1)
NEW (PN 7547831 – QTY 2)
TORQUE
TORQUE
250 lb-ft (339 Nm)
Inside Nut: 250 lb-ft (339 Nm)
Outside Nut: 150 lb-ft (203 Nm)
Loctite® 641 (Yellow)
Loctite® 680 (Green)
The information contained within this Team Tip is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. This Team Tip is provided for the sole use
of authorized Polaris dealers and distributors. This Team Tip is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2015 Polaris Industries Inc. (Page 1 of 1)
SLI-15-05
2015-2016
11/24/2015
X
IMPORTANT SAFETY NOTICE!
STOP SALE
SUBJECT: 2015-2016 Slingshot / Slingshot SL – Headlight Jumper Harness Installation
PURPOSE:
Polaris has determined that some Slingshot vehicles were manufactured with a headlight circuit that does not meet
Polaris quality standards. In some vehicles, heat buildup in the engine compartment may cause the headlight circuit relay
to derate below the required current draw of the headlights. In addition, temperatures produced at the fuse box terminal
pin may be higher than desired. The result of such a condition could be a loss of forward lighting function. This could
cause decreased visibility for the vehicle operator, increasing the risk of a vehicle crash.
POTENTIALLY AFFECTED MODELS:
2015-2016 Slingshot and Slingshot SL models manufactured on or before 10/26/2015.
Use ‘Unit Inquiry’ or the Service Bulletin VIN Lookup tool on the STOP Site to identify affected vehicles.
WHAT YOUR DEALERSHIP SHOULD DO:
1. STOP ALL SALES / TEST RIDES / DEMO RIDES until this Safety Bulletin has been completed on affected units.
After the bulletin is completed and a warranty claim has been filed, it is acceptable to resume sales / test rides /
demo rides.
2. Review your dealership’s inventory to locate potentially affected models.
a. Use ‘Unit Inquiry’.
OR
b. Login to the dealer website.
c. Locate the ‘Service and Warranty’ dropdown, click on STOP Site.
d. On the left hand side of the page, under ‘STOP Site Links’, click on ‘Service Bulletins’.
e. Locate the SLI-15-05 link and click on the ‘All VINs’ link located on the right.
f. The ‘All VINs’ page will display all affected VINs within your dealership’s inventory.
3. Perform the headlight jumper harness inspection and installation procedure outlined in this Safety Bulletin on all
affected units.
4. File a warranty claim following completion and attach a bulletin completion decal as shown on page 2 of this
bulletin.
CUSTOMER NOTIFICATION:
A customer notification letter will be sent to all registered owners of affected vehicles. In addition to the notification letter
sent by Polaris, dealers are required to review sales records and contact consumers who have purchased a potentially
affected vehicle. Make arrangements to perform the steps outlined in this Safety Bulletin immediately.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 1 of 6)
PARTS / WARRANTY CLAIM 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 #
SLI-15-05
CLAIM TYPE
SB (Service Bulletin)
LABOR ALLOWANCE
30 Minutes (0.5 Hours)
PART NUMBER / DESCRIPTION
7170107 (QTY.1) – Service Bulletin Completion Decal
2881939 (QTY.1) – Kit-Headlight, Relay Jumper
PARTS AVAILABILITY
Available to order
DIRECT-SHIP FROM POLARIS?
No
TO BE ORDERED BY DEALER?
Yes
PARTS RETURN OR DISPOSAL INFORMATION:
International Dealers & Distributors: Under no circumstances shall the part(s) removed in this repair be re-used, sold,
or re-purposed for another application. It is your dealership / distributorship’s responsibility to make sure every part
replaced is taken out of circulation and disposed of properly.
For North American Dealers: 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.
SERVICE BULLETIN COMPLETION DECAL:
A Service Bulletin Completion Decal (PN 7170107) must be
completed for this bulletin repair. Place the decal on the left side
frame tube, near the brake master cylinder (as shown). 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 Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 2 of 6)
FUSE BOX INSPECTION PROCEDURE
1. Park the vehicle on a level surface and apply the parking
brake. Raise the hood.
2. Remove the fuse box cover.
3. Remove the Primary Light Relay. Inspect the fuse box pins
for damage.
4. If no damage is observed, proceed to HEADLIGHT
JUMPER HARNESS INSTALLATION procedure.
5. If damage is observed, photograph the damaged pins and
submit an Ask Polaris case for further guidance before
beginning installation procedure.
INSTALLATION VIDEO
An installation video is available for this procedure.
Click or enter the following link into your browser:
http://www.tcelearning.com/SSLH/SlingshotAuxLightHarnessInstall.htm
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 3 of 6)
HEADLIGHT JUMPER HARNESS INSTALLATION
REQUIRED TOOLS
• Socket Wrench,
• Hex Socket: 10 mm
• Torx Drive: T-40
• Torque Wrench
• Allen Drive: 5 mm
• Side Cutting Pliers
INSTALLATION INSTRUCTIONS
1. Park the vehicle on a level surface and apply the parking
brake. Raise the hood.
2. Disconnect the negative (-) battery cable.
3. Route the jumper electrical harness (yellow) alongside the
main electrical harness (blue) from the fuse box forward to
the RH and LH auxiliary outer lights.
(Canadian Models: RH and LH outer headlights)
NOTE: Align all white tape markers on jumper harness with
existing locations on main harness.
4. Cut the zip tie holding the main harness auxiliary light
connector above the RH and LH auxiliary outer lights
(Canadian Models: RH and LH outer headlights).
5. Unplug the RH and LH outer light connectors. Plug the
jumper harness two-wire connector into the auxiliary light
connector. Plug the jumper harness single wire connector
into the remaining main harness connector.
6. Zip tie the connectors from the main harness and jumper
harness together using the existing tie point on the frame.
7. Zip tie jumper harness to main harness at existing white tape
marks ①.
8. Zip tie jumper harness to main harness at location ②.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 4 of 6)
9. Remove the (2) fasteners securing the ECU to the vehicle
using a 10 mm socket. Rotate the ECU out of the way.
10. Remove the fuse box lid.
11. Remove the (2) fasteners securing the fuse box to the
mounting block using a 5 mm Allen drive.
12. Cut the zip tie holding the wire harness to the front side of
the mounting block.
13. Remove the (3) fasteners securing the mounting block to the
frame using a T-40 Torx drive. Rotate the mounting block out
of the way.
th
14. Remove the 4 blue wire clamp from the left when looking at
the fuse box from the front.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 5 of 6)
15. Remove plug from fuse box terminal #45 ② by inserting a
zip tie through the front of the fuse box terminal to push the
terminal plug out.
NOTE: This is the only terminal without a wire running to it.
CAUTION: Do NOT bend circuit breakers or relays to avoid
damage.
16. Reinstall the fuse box cover to protect components while
installing the new terminal.
17. Push terminal connector from jumper harness into fuse box
terminal #45 until the terminal clicks into place. Place light
tension on the wire to ensure the connector is fully seated
and engaged in the terminal.
NOTE: Reference the orientation of the terminal connectors
already installed in the fuse box and match this orientation
when installing the jumper harness terminal connector.
CAUTION: Do NOT force the terminal connector into position
as it should slide in with little force. If it does not install easily,
review orientation and try again.
18. Reattach the blue wire clamp.
19. Install the ECU mounting block and fasteners.
Torque fasteners to specification.
TORQUE:
ECU Mounting Block Fasteners: 3 lb-ft (4 Nm)
20. Install new a zip tie holding the jumper harness and main
harness to the front side of the ECU mounting block.
21. Remove fuse box cover. Install the fuse box and fasteners.
Torque fasteners to specification.
TORQUE:
Fuse Box Fasteners: 7 lb-ft (9.5 Nm)
22. Install the ECU and fasteners. Torque to specification.
TORQUE:
ECU Fasteners: 7.5 lb-ft (10 Nm)
23. Replace current fuse location decal on inside of fuse box
cover with new decal provided in the kit.
24. Install new auxiliary light relay and auxiliary light fuse into
fuse box locations as outlined by the new decal. Replace
current primary light relay with new relay provided in the kit.
25. Install fuse box cover.
26. Install battery negative (-) cable.
27. Test and verify headlight operation.
The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. 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.
© 2015 Polaris Industries Inc. (Page 6 of 6)
IMPORTANT SAFETY RECALL
This notice applies to your vehicle
VIN:
Slingshot Division
Polaris Industries Inc.
P.O. Box 47700
Medina, MN 55340-9960
Recall Campaign: 15V-777
Subject: 2015-2016 Slingshot
Headlight Jumper Harness Installation
PLEASE READ IMMEDIATELY
Dear Slingshot Owner:
tte
r
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. The Slingshot
Division of Polaris Industries Inc. has decided that a defect which relates to motor vehicle safety exists in some 2015 and 2016
Slingshot vehicles. Our records indicate that you have purchased a potentially affected vehicle.
Le
The reason for this recall:
Polaris has determined that some Slingshot vehicles were manufactured with a headlight circuit that does not meet Polaris quality
standards. In some vehicles, heat buildup in the engine compartment may cause the headlight circuit relay to derate below the required
current draw of the headlights. In addition, temperatures produced at the fuse box terminal pin may be higher than desired. The result
of such a condition could be a loss of forward lighting function. This could cause decreased visibility for the vehicle operator, increasing
the risk of a vehicle crash.
su
m
er
What Polaris and your dealer will do:
Polaris will issue a Safety Recall Bulletin to all Slingshot dealers, with the appropriate instructions to install an auxiliary headlight jumper
harness. Repairs will be made by an authorized Slingshot dealer at no cost to you. The actual repair should take under one hour to
perform; however, it may take longer due to service scheduling requirements.
What you should do:
Contact your authorized Slingshot dealer to schedule an appointment to have the bulletin repairs performed. Do not attempt repairs
yourself. Repairs must be done only by an authorized Slingshot dealer.
.S
.C
on
If you have questions or if you need more information:
While your Slingshot dealer is in the best position to answer your questions, if you have any questions that your dealer cannot address,
if you are having difficulty obtaining the recall repair outlined in this letter, or if you need assistance finding a Slingshot dealer, please
visit the Slingshot web site at http://www.polaris.com/en-us/slingshot or contact our Slingshot Consumer Service Department by calling
1-855-863-2284.
This notice was mailed to you according to our most current registration information. If you no longer own your Slingshot vehicle, please
contact your local Slingshot dealer to have the ownership information changed. The Slingshot Consumer Service Department cannot
change ownership information without identification. Federal law requires that any vehicle lessor receiving this recall notice must
forward a copy of this notice to the lessee within 10 days.
U
If you have had this repair performed before you received this letter, you may be eligible to receive reimbursement for the cost of
obtaining a pre-notification remedy of the problem associated with this recall. For more information regarding reimbursement please
contact your Slingshot dealer or the Slingshot Consumer Service Department using the information above.
If you believe that the Slingshot Division of Polaris Industries Inc. has failed to remedy this defect without charge or is unable to do so
within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Avenue SE., Washington, D.C. 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or
on the web go to http://www.safercar.gov.
Please accept our apologies for any inconvenience this may cause you. Your safety and continued satisfaction with your Slingshot is
our primary concern. Thank you for your prompt attention to this matter.
Sincerely,
Polaris On-Road Vehicles
Polaris Service Newsletter
Service News: "11/30/2015"
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FEATURED EMPLOYEE
RECENT FIELD COMMUNICATIONS
The following list includes recently released Team Tips, Safety Bulletins,
Service Advisories, Service Alerts,and Voice of Victory. Please take the time
to visit the dealer STOP Site and familiarize yourself with them.
Each month the North Star
Service Solutions Newsletter
features a member of the Polaris
team. This month's featured team
member is Ron Haselius.
Safety Bulletins
I-15-04 A-B
Indian® Safety Bulletin I-15-04 Released
Some 2015-2016 Indian® Full-Size motorcycles have been manufactured
with a rear brake master cylinder that does not meet Indian
Motorcycle® quality standards. In some vehicles, the rear brake master
cylinder piston cup may develop a tear.
SLI-15-05
Slingshot Safety Bulletin SLI-15-05 Released
Some Slingshot vehicles were manufactured with a headlight circuit that does
not meet Polaris quality standards. In some vehicles, heat buildup in the
engine compartment may cause the headlight circuit relay to derate below the Ron has been with Polaris for
required current draw of the headlights.
one year as a member of Polaris’
Team Tips
A-15-10-01
Team Tip A-15-10-01 Released
This Team Tip has been released to assist with the diagnosis of trouble code
P1135 - ETC Accelerator Position Fault (SPN 65613 FMI 2). Affects 2015
Sportsman 570 International models equipped with Electronic Throttle
Control..
SLI-15-11-01
Team Tip SLI-15-11-01 Released
The Slingshot Division of Polaris Industries has developed updated rear
sprocket retaining nuts and Loctite® on 2016 Slingshot models manufactured
after 11/02/2015.
Service Advisories
ASA-15-01
2016 Sportsman 570 Hunter Edition Front/Rear Brush Bumpers
This Service Advisory has been issued to communicate a specific warranty
claim process which empowers dealers to resolve a manufacturing error
without requiring pre-authorization from Polaris.
RSA-15-01
2015 RANGER XP 900 EPS High Lifter Edition - Missing Winch Remote
Polaris has learned that a select number of 2015 RANGER XP 900 EPS High
in-house 3D/CGI Studio. I this
role, he creates the computergenerated images and technical
animations of Polaris’ vehicles for
the web, catalogs, and banners.
Before coming to Polaris, Ron did
3D
visualizations
in
the
architecture and engineering
fields. He created large virtual
models
for
numerous
architectural firms.
Outside of work, Ron's interests
include Drum & Bugle Corps
competitions, astronomy, and
architecture.
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Lifter Edition units were shipped without the handheld remote switch for the
winch, 4013466.
NEWS AND INFORMATION
New Vehicle Down Order (VDO) and Priority Handling Order (PHO) Policies
The new Vehicle Down Order (VDO) and Priority Handling Order (PHO) Policies are located under News, Forms & Links >
PG&A. Every effort will be made to fill Vehicle Down Orders within one business day using all resources within Polaris. In
the event the order cannot be filled, items will ship through normal channels when the item becomes available.
• There is no added cost associated with the new VDO Program. A VDO cannot be submitted for in-stock / available
parts. If the item is in stock and must be shipped same day, please refer to the PHO Policy for details.
• There is an additional cost to the freight on the new PHO Program. The PHO must be in, and credit approved by
1:00pm CST for guaranteed same-day shipping.
• Regular customer orders do not guarantee same-day shipping.
If you need to check status on a submitted VDO, please allow two business days after the order is submitted to review the
auto-generated ASK Polaris case. To view, go to PGA > Purchase Order Inquiry then locate the order and select it to
access the case link. You will need to check your purchase order inquiry for confirmation of the order status. Please keep in
mind that a VDO does not guarantee that Polaris will fulfill the submitted order. If you have questions about the VDO or
PHO Policies, please contact Polaris using ASK Polaris > Non-Tech Parts.
ORV Multipoint Checklist
Polaris has released a multipoint checklist for ORV products that walks through a baseline inspection when a vehicle
comes in for service. This form may be found in Service and Warranty - News, Forms and Links.
Click here: ORV Multipoint Checklist
Warranty Claim Issues
When creating claims from ASK Polaris cases, if the claim fails, or it seems that the claim did not go through, don't forget to
check the Finish A Claim and Fix A Claim areas on your dealer website.
On your dealer homepage, access the "Service & Warranty" drop-down menu and click the link that says "Start a New
Warranty Claim." This is to create a warranty claim, but it is also where unresolved claims are found.
•
•
The Finish A Warranty Claim area is where claims are found that were not completed, or haven't been fully
processed yet. If a claim gets created from an ASK Polaris case, and you closed one of the windows before the
claim was able to process, or if there was a hiccup in your internet, check to see if the claim ended up here. If so,
click the claim number and then click "Send Claim" to finish the process.
The Fix A Warranty Claim area contains claims that have errors. For instance, if a claim is out of warranty, or the
wrong type of warranty claim was selected in the claim, it will end up here. Often times, a vehicle will go out of
warranty between the time when an Warranty Authorization case was approved, and the time that the claim was
created. This will cause the claim to fail as the claim was originally set up as a standard claim, but now the vehicle
is out of the standard warranty period. If this happens,it is possible to go back to the ASK Polaris case that this
claim was created from, reactivate it, and notify Polaris of the claim failure. Otherwise, create a new case, or call
to have the claim manually pushed through.
Tips on Service Reports
When troubleshooting an issue with a vehicle and looking for assistance from Polaris Tech Service, it's important to
become familiar with how to capture and send service reports, as long as the vehicle is compatible with Digital Wrench.
Here are a few tips and facts to remember when using this feature in Digital Wrench:
•
Dealer Number - Make sure that your dealer name and dealer number are set up properly in the Digital Wrench
settings. After Digital Wrench has opened, there is a button with a Crescent Wrench on it; click that button to
access the System Configuration. This page has multiple items, including your dealership information. Ensure that
the "Dealer Number" field has your five-digit dealer number, and "00" after it for domestic dealers, or "01"after it for
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Canada. If your number is not in this format, it will prevent Service Reports from being sent to the Unit Inquiry
feature on the Polaris dealer website.
•
"View Current" Feature - When you first double-click on the word "Service Report" to go into the feature, that's
when it captures the first service report. Once you are in the Service Report feature, click on the "View Current"
button in the window to capture a new snapshot of the readings at that moment; then you are able to view, send,
and/or save the new report. Using the "View Current" feature can be especially helpful when trying to capture a
report at the split second that a vehicle is exhibiting a certain behavior.
•
Vehicle "Birth certificates" - It is important to create and send service reports on new vehicles during PDI before
they leave your dealership, these reports are often called "Birth Certificates." Birth Certificates offer a view of what
a vehicle's sensor data looked like when the vehicle was in proper working condition, for comparison to other
reports (if the vehicle is ever in the shop for run-ability issues in the future).
•
"Wrong Vehicle Selected" Feature - Whenever you get the error message, "Wrong Vehicle Selected", you can
still send a service report. Digital Wrench thinks that you've selected the wrong vehicle, but this means that it is
reading the ECU, and it sees that the model number clashes with the vehicle year and model that you selected.
When this message is displayed, it still allows you to click on the Special Test menu and select the Service Report
feature. From there, you can create, view, send and save reports.
Please refer to Team Tip G-11-01-02 for further instruction on sending Service Reports and other tips.
Introducing the NEW Polaris Dealer Equipment and Services Program!
Polaris dealers are the key to success the of Polaris' growth in both units sold, and product lines offered. To continue to
provide the service and support customers expect, dealers are updating and expanding their service facilities. Dealers are
looking for new service equipment from Polaris to ensure they are maximizing their service department's efficiency, safety,
and profitability. To achieve this, Polaris Industries, Inc. teamed up with Bosch Automotive Service Solutions, Inc. to launch
the Polaris Dealer Equipment Program at the 2015 Summer Sales Meeting.
"Working with Polaris to develop a program that would meet the needs of the dealers, over a 12 month period we visited
dealers across the U.S. and Canada. Through our visits, we were able to put together, and launch, an Equipment&
Services Program. The program gives dealers easy access to the Polaris approved equipment required to properly service
new products, such as the Slingshot and larger Ranger & RXR Off-Road vehicles, as well as offering a specialized facility
planning service which can help every dealer build an efficient service and parts department." -Clint Perry, Regional Key
Account Manager at Bosch.
This program is tailored for the Powersports industry, specifically
Polaris dealers. Purchase from the program with piece of mind
knowing that the equipment and products have been reviewed and
approved for use specifically with Polaris products.
Through this program, Bosch is bringing a number of key features
and benefits to Polaris dealers, including:
•
•
•
•
One-stop-shopping for overall service equipment needs for
dealers.
Access to thousands of authorized products and equipment for
servicing Polaris vehicles.
Strong purchasing power and a source for dealership equipment
service and product warranty questions.
Ongoing promotions, product updates, and an online equipment catalog.
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•
•
•
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Equipment and systems planning: free facility planning for all Service and Parts Department areas when the
program is utilized to outfit the areas being developed.
Experienced personnel: localized Sales Representatives providing individual attention to your dealership needs
(see website for contact information).
Competitive financing and leasing options.
Visit the US program online catalog at www.PolarisDealerSolutions.com or by calling 1-855-804-7390. There is currently
an ongoing promotion through the end of 2015 with special pricing on wheel and tire service equipment, lifts, and a variety
of other items.
Attention Indian Technicians!
Are you looking for some extra $$ this holiday season? Would you like to have your voice heard and contribute to the
creation of Indian® MSD Gold? Here's your chance to share your experiences with the rest of the community by
answering seven quick questions.
We will draw five names at random and send out five Visa gift cards. One winner will receive a $100 gift card and four
lucky additional winners will receive $50 gift cards. BUT - you must be Indian Silver certified to be eligible.
So, here's what you need to do:
1.
2.
3.
Be Indian® MSD Silver certified.
Visit https://www.surveymonkey.com/r/Indian-Gold-Survey by December 15th, 2015.
Be awesome and share your experiences.
Introducing the Polaris GENERAL™, the New Standard in Off-Road
Versatility
The 2016 Polaris GENERAL 1000 EPS will be arriving
in dealerships soon. A Service Communication Poster
outlining vehicle service publications, tools and training
has been posted on the dealer website under News,
Forms & Links in the Service and Warranty dropdown.
Review the poster for an overview of service
requirements on the new standard in off-road versatility.
2016 Gold Master Service Dealer (MSD) Classes
Gold MSD classes for the first half of 2016 are now posted to www.univresityofpolaris.com. Please register early as classes
fill fast and seats are limited on a first come, first served basis.
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MSD Classroom Training Schedule
To check your MSD status or check training schedules, please refer to the Dealer Dashboard (Dealer Website> Service
and Warranty) or information is also available 24/7 on www.universityofpolaris.com.
If you do not find an answer to your question, do not hesitate to enter an ASK Polaris case or call Dealer Services at 1-800330-9407.
2015 December All Classes 8:00 AM-5:00 PM
ORV GOLD
Plymouth, MN
Dec. 8-11
SNOW GOLD
Canton, NY
Dec. 8-10
November Tablet Winner
All new subscribers whom signed up between August 1, 2015 and November 19, 2015 were entered into a drawing for a
tablet computer. The winner is John MacAusland at Polaris of Cornwall PE.
TRIVIA
For a chance to win, correctly respond via email to the trivia below with the answer to the question by December 10,
2015. Please include the address of your dealership in your email and your first and last name. You will be entered into this
month's prize drawing.
Submit trivia responses to:
[email protected]
October Trivia Answer
In 2005 Polaris went into partnership with which Austrian power-sports firm?
Answer: KTM
Congratulations to Matthew Matkovic at Polaris of Cochrane, AB for answering the October trivia question
correctly! Look for your prize in the mail!
November Trivia
Polaris ATV vehicles may display trouble code P1135, what does this code mean?
Register a friend | Unsubscribe
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Polaris Service Newsletter
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The information contained within this email 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.© 2015 Polaris Industries Inc.
© 2015 Polaris Industries Inc.
2100 Highway 55, Medina, MN 55340, USA
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