SLG-05.11.2023

SLINGSHOT SETUP INSTRUCTION
P/N 9931485
APPLICATION
Slingshot S / SL / SLR / R / GT / LE
TOOLS NEEDED
• Hex Sockets: 13 mm, 18 mm
• Small Diameter Screwdriver
• Allen Wrench: 8 mm
• Side Cutting Pliers
• Ratchet Wrench
• Torque Wrench
SETUP TIME
Approximately: 10 min
SETUP INSPECTION
STOP!
Inspect the vehicle for any apparent damage, concealed damage, or missing components. If damage or
missing components are found, refer to the General Service Info - Damage Claims document for more
information.
IMPORTANT INFORMATION
Setup and Pre-Delivery service must be performed by an authorized Polaris dealer. Proper pre-delivery is
essential to reliability of the vehicle and to rider safety. An error made by the person setting up and servicing a
new vehicle can result in damage to the machine or injury to the rider. Perform all items correctly and completely.
Observe all safety precautions when assembling this vehicle. Always follow torque specifications as outlined.
Incorrect torquing may lead to serious machine damage or can result in injury or death for the rider.
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/video. The form is viewable on mobile devices by
scanning the QR code or on a PC by clicking HERE.
Instr 9931485
Rev 02
Page 1 of 14
UNPACKING THE VEHICLE
1. Remove the kit bag from the glovebox and verify
components.
3. Remove ratchet strap from rear shock. To remove,
tighten ratchet drive nut with 18 mm socket
clockwise and insert small diameter screwdriver
through hole to pry lock bar away from cam to
release.
• Owner’s Manual
• Fuse Puller with Spare Fuses
• Side Mirror Bolts (4)
*Depending on vehicle build date, extra fasteners
may be included in the kit bag. These fasteners
can be discarded.
2. Remove and discard roll hoop protectors.
Instr 9931485
NOTICE
Make sure to remove the cardboard and additional
strap sleeve that is sticking out of the plastic panel.
4. Remove the floor mats, hang tag, and protective
steering wheel wrap.
Rev 02
Page 2 of 14
• Remove the fasteners q securing the windshield to
the frame. Remove the film from both sides of the
windshield.
5. Remove the protective film from the windshield.
NOTICE
If the windshield film is located under the fasteners,
then follow the instructions to remove and install the
windshield.
• Slide both the driver and passenger windshield tabs
into the frame.
• Install the fasteners q securing the windshield to
the frame. Tighten windshield to frame fasteners
until taught. Torque windshield support fastener to
specification.
TORQUE
Windshield Support Fastener:
9 in-lbs (1 N·m)
CAUTION
Do NOT overtighten windshield fasteners or
windshield could crack.
Instr 9931485
Rev 02
Page 3 of 14
MIRROR INSTALLATION
1. Remove the mirrors from the driver and passenger
storage compartments.
3. Align and install the mirrors to the mount with
fasteners from kit bag using an 8 mm Allen
wrench. Torque fasteners q to specification.
2. Install the mirror dampers as shown (if applicable).
TORQUE
Side Mirror Base Fasteners:
34 ft-lbs (47 N·m)
NOTICE
Roush Edition models: Fasten the mirror directly to
the Excursion frame. Align notch and torque to
specification.
Mirror Mounting Screw:
27 ft-lbs (36.5 N·m)
4. Adjust the mirror heads to proper rear viewing
angle and secure position using a 13 mm socket.
Torque pivot fastener w to specification. Clean
mirrors.
TORQUE
Side Mirror Pivot Fasteners:
27 ft-lbs (37 N·m)
5. Repeat steps 2–4 for the other mirror.
Instr 9931485
Rev 02
Page 4 of 14
PRODUCTION STICKER REMOVAL
When vehicle assembly is completed, there are
barcode stickers that are used for production located
on many of the vehicle components. These stickers
should be removed before delivery. These stickers
can be located on, but not limited to,
• Wheels
• Dash Panels
• Exterior Trim Panels (Accent Panels, Frog Skinz
Panels, Gas Cap, ETC.
• Exterior Lighting (Headlights, Tail Lights)
• Body Panels (Front Fascia, Fenders, Filler Panels,
ETC.)
• Seats, or Seat Base
The sticker will look similar to the image shown below.
When the sticker is removed there may be left over
residue. This should be cleaned using hot soapy
water, or adhesive removers that will not damage the
finish.
CAUTION
Do not use a razor blade, scraper, or any metal
objects to remove the sticker or adhesive. This will
damage the finish on the part the sticker is being
removed from.
Instr 9931485
Rev 02
Page 5 of 14
PRE-DELIVERY INSPECTION
NOTICE
If the vehicle is being displayed or stored prior to
retail, these items should be re-inspected during the
PCDX process and prior to customer delivery.
7. Remove dipstick and check that the oil level is
between the ADD and FULL line. Add oil as
necessary to bring the level to the safe zone on
the dipstick. Do not overfill.
ENGINE OIL LEVEL
This engine is a wet-sump engine, meaning the oil is
contained in the bottom of the crankcase. To check
the oil level, follow the procedure listed below.
NOTICE
The engine must be at normal operating temperature
when checking or changing the oil. Do not check or
change the oil when the engine is cold.
1. Position the vehicle on a level surface. Place the
transmission in neutral. Engage the park brake.
2. Start the engine and allow it to idle for 2-3 minutes.
Stop the engine.
3. Wait 3 minutes before checking the oil level. This
allows the oil to settle to the bottom of the
crankcase. Do not check the oil level immediately
after stopping the engine.
4. Push the hood release handle and lift the hood
forward.
5. Remove the dipstick. Wipe dry with a clean cloth.
6. Reinstall the dipstick. Make sure it’s fully seated.
NOTICE
If oil level is at “ADD”, about 1 qt. (946 ml) is needed
to reach the “FULL” mark.
FLUID CAPACITY
Use only Full Synthetic SAE 5W-50 oil as specified.
NOTICE
A rising oil level between checks in cool weather
driving can indicate contaminants such as fuel or
moisture collecting in the crankcase. If the oil level is
over the full mark, change the oil immediately.
NOTICE
Make certain the dipstick is inserted all the way into
the filler tube to produce consistent oil level
readings.
Instr 9931485
Rev 02
Page 6 of 14
COOLANT LEVEL INSPECTION
The pressure cap q and surge tank w are located
6. Reinstall the pressure cap.
NOTICE
under the hood of the vehicle near the firewall.
Use of a non-standard pressure cap will not allow the
cooling system to function properly.
7. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.
BRAKE FLUID INSPECTION
Always check the brake pedal travel and inspect the
brake fluid reservoir level before each operation. If the
fluid level is low, add DOT 4 brake fluid only.
The brake fluid master cylinder reservoir can be
accessed front the driver side of the engine
compartment.
The coolant level must be maintained to the level
indicated on the surge tank. The surge tank cap acts
as the pressure cap for the radiator as well. Therefore,
the surge tank is pressurized to 15 psi (103 kPa).
With the engine off and cold, the coolant level should
be at the cold fill level indicated on the coolant surge
tank. If not, perform the following procedure:
1. Position the vehicle on a level surface.
2. Place the transmission in gear.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line,
add brake fluid until it reaches the MAX level line.
1. Position the vehicle on a level surface.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
2. Push the hood release handle and lift the hood
forward.
3. View the coolant level in the surge tank.
4. If the coolant level is below the line, remove surge
tank / pressure cap.
NOTICE
If overheating is evident, allow system to cool
completely and check coolant level in surge tank and
inspect for signs of trapped air in system.
WARNING
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe
burns. The engine must be cool before removing the
pressure cap.
5. Fill surge tank to the level line with recommended
coolant or 50/50 mixture of antifreeze and distilled
water as required for freeze protection in your
area.
FLUID CAPACITY
Recommended Coolant: 50/50 Extended Life
Pre-Mixed Antifreeze
Coolant Capacity: 4.75 qt (4.5 L)
Instr 9931485
Rev 02
Page 7 of 14
TIRE PRESSURE
Remove the valve stem cap q and check tire
pressure using the tire pressure gauge included in the
vehicle’s tool kit.
CLUTCH FLUID INSPECTION (MANUAL
TRANSMISSION)
Always check the clutch pedal travel and inspect the
clutch fluid reservoir level before each operation. If the
fluid level is low, add DOT 4 brake fluid only.
The remote clutch fluid reservoir q is on the driver
side of the engine compartment.
CAUTION
Maintain proper tire pressure.Refer to the warning
tire pressure decal applied to the vehicle.
TIRE PRESSURE INSPECTION (COLD)
Front: 28 ± 2 PSI (193 ± 14 kPa)
Rear: 32 ± 2 PSI (221 ± 14 kPa)
1. Position the vehicle on a level surface.
2. Place the transmission in gear.
3. View the clutch fluid level in the reservoir. The
level should be between the MAX and MIN level
lines.
4. If the fluid level is lower than the MIN level line,
add clutch fluid until it reaches the MAX level line.
NOTICE
Clutch pedal should be lifted up to full out position.
5. Install the reservoir cap and apply the clutch pedal
forcefully for a few seconds and check for fluid
leakage around the clutch master cylinder fittings.
Instr 9931485
Rev 02
Page 8 of 14
TRANSMISSION FLUID LEVEL CHECK
ANGLE DRIVE OIL LEVEL CHECK
To inspect the oil level, the fill plug q is located on the
This fluid level does not require routine inspection. If
gear shifting seems irregular or if you suspect a fluid
leak, inspect the fluid level.
driver side of the angle drive housing.
If the level does need to be inspected, the fill plug q
is located on the rear, driver side of the transmission
housing.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the oil level.
Inspect O-ring for any damage and replace if
necessary
1. Position vehicle on a level surface.
2. Remove the fill plug and check the lubricant level.
3. If lubricant level is not within 5 mm to the bottom
edge of fill hole, add recommended lubricant as
needed. Do not overfill.
3. If lubricant level is not at the bottom edge of fill
hole, use a syringe to add recommended lubricant
as needed. Do not overfill. If a syringe is not
available, use a funnel and tube.
FLUID CAPACITY
Recommended Angle Drive Oil: SAE 85W-250
(PN 2889023 - Qt)
Capacity: 0.78 qt (700 mL)
FLUID CAPACITY
Recommended Transmission Lubricant:
GL-3 (PN 2879440 - Qt)
Capacity: 2.75 Qt (2.6 L)
4. Reinstall the fill plug and torque to specification.
4. Reinstall the fill plug and torque to specification.
TORQUE
TORQUE
Angle Drive Fill / Drain Plug:
12 ft-lbs (16 N·m)
Trans Fill / Drain Plug:
27 ft-lbs (37 N·m)
FRONT FASCIA INSPECTION
1. Inspect the hood to fascia alignment to ensure no
damage has occurred during shipping. Reference
Front Fascia Alignment if adjustment is required.
Instr 9931485
Rev 02
Page 9 of 14
REFERENCE INFORMATION
CLUTCH LEARN (AUTODRIVE ONLY)
MASTER PIN RETRIEVAL
2020–2021
1. Connect Digital Wrench II® and turn power switch
to "ON" position. Do NOT start the engine.
1. Press the start button twice to power the vehicle to
Ignition Mode.
2. On a flat smooth surface, accelerate from a full
stop sufficiently so the system shifts to 2nd gear at
a minimum of 21mph to achieve the necessary
torque for the clutch learn. Then deccelerate to a
full stop for at least 2 seconds.
IMPORTANT
Repeat this step ten times.
3. Shut the ignition off, pull the park brake and wait
for 15 seconds to allow for the system to save the
new clutch position. Do not depress the brake
during this time as it will prevent full clutch learn.
2022+
2022+ AutoDrive models have had the clutch learn
performed as part of the manufacturing process and
therefor no action is required.
BRAKE BURNISHING PROCEDURE
It is required that a burnishing procedure be
performed for new vehicles to achieve consistent
braking, extend service life, and reduce noise.
Start the Machine and accelerate to greater than 40
mph. Moderate aggressively apply brakes to slow the
vehicle to less than 10 mph but do not stop.
Accelerate again to above 40 mph and repeat the
process 10 times.
IMPORTANT
Do not stop aggressively or skid the wheels as the
burnishing will be uneven. Do not slow to a complete
stop as this may create hot spots on the rotors and
damage the pads.
2. In Digital Wrench II®, select "Procedures”, next
select "Key fob Maintenance”.
3. Record the master PIN in the PDI / PCDX form.
ACTIVATE KEY FOB SECURITY
1. Connect Digital Wrench II® and turn power switch
to "ON" position. Do NOT start the engine.
2. In Digital Wrench II®, select "Procedures >
Slingshot Configuration > Security Configuration >
"Enable Key Fob Security”
REFERENCE - TORQUE SPECIFICATIONS
DESCRIPTION
Windshield Support
Fastener
9 in-lbs (1 N·m)
Side Mirror Base
Fasteners
34 ft-lbs (47 N·m)
Side Mirror Pivot
Fasteners
27 ft-lbs (37 N·m)
Trans Fill / Drain Plug
27 ft-lbs (37 N·m)
Angle Drive Fill / Drain
Plug
12 ft-lbs (16 N·m)
ADDITIONAL PARTS / INFORMATION
Mirrors are located in the driver-side and
passenger-side compartment
After the burnishing process is complete, drive the
vehicle to cool the brake pads and rotors.
NOTICE
The burnishing process may cause there to be brake
dust on the wheels and calipers. This is normal.
When the system has cooled, use a rag and water to
clean the wheels and calipers
Instr 9931485
TORQUE
Rev 02
Page 10 of 14
HOOD / FRONT FASCIA ALIGNMENT INSPECTION
HOOD
Inspect the hood to body panel alignment for appropriate alignment gap. Reference the images below
for pass / fail examples.
NOTICE
Commercially available gap gauges are available to order online and can be used to achieve an even gap
during hood alignment.
Inspect for excessive gap or zero tolerance between the hood and body panel.
PASS
FAIL
Excessive Gap
Gap of 3–10 mm between the hood and body panel
Narrow Gap
Instr 9931485
Rev 02
Page 11 of 14
FRONT FASCIA
Inspect for excessive gap or zero tolerance where the front fascia meets the hood. Measure at the front
tip, as indicated by the green arrows in the photos below.
PASS
FAIL
Excessive Gap
• Standard Hood: Gap of 6–9 mm between the front
fascia and the hood
• Vented Hood: Gap of 9–11 mm between the front
fascia and the hood
Narrow Gap
• If not within range, adjust the hood and / or front fascia. See next pages for adjustment instructions.
Instr 9931485
Rev 02
Page 12 of 14
HOOD ADJUSTMENT
IMPORTANT
1. Loosen hood hinge fasteners q.
Always verify proper hood latching following hood
alignment adjustment
• Make sure both front hood pins are properly
engaged.
• Check engagement with both the front and rear
latches.
• Tug on hood to make sure hood is fully engaged.
6. Torque front hood latch mount fasteners w to
specification.
TORQUE
Front Hood Latch Mount Fasteners:
18 ft-lbs (24 N·m)
2. Loosen front latch mount fasteners w.
7. Torque hood hinge fasteners q to specification.
TORQUE
Hood Hinge Fasteners:
18 ft-lbs (24 N·m)
3. Close hood.
4. Check both sides of the hood for proper hood gap
between the hood and fender.
MEASUREMENT
1/8"-3/8" (3-10 mm)
5. Check front latch engagement.
Instr 9931485
Rev 02
Page 13 of 14
FRONT FASCIA ADJUSTMENT
IMPORTANT
NOTICE
The hood must be closed and all four hood latches
must be engaged prior to adjusting the front fascia.
Inspect the lower clip tube tabs for damage. If they
are bent over from front collision, the bar will need to
be replaced.
1. Loosen the three fascia bracket bolts.
HOOD TO FASCIA GAP:
STANDARD HOOD
VENTED HOOD
6–9mm up/down q
5–10mm fore/aft w
9–11mm up/down q
5–10mm fore/aft w
NOTICE
The slots allow for up/down and forward/back
movement of the fascia assembly.
2. Adjust the fascia so the hood overlaps the fascia
slightly to the specified measurements.
3. Torque all three fasteners to specification.
TORQUE
MOUNT BRACKET, FRONT UPPER, FASTENERS
84 in-lbs (9 N·m)
TORQUE
SUBFRAME SUPPORT FASTENER
18 ft-lbs (24 N·m)
4. Repeat steps 1–3 on the other side if adjustments
are required.
Instr 9931485
Rev 02
Page 14 of 14