I-19-02 - Loss of Headlight Function - 2014 Indian Chief & Chieftain

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I-19-02-B VCM REPLACEMENT AND PIN REPAIR
KIT CONTENTS (P/N 2208321)
REF PART DESCRIPTION PART NUMBER QTY
q Vehicle Control Module (VCM) 4016189 1
w Heat Shrink Tube 2410766 1
e VCM Connector Assembly 2415294 1
TOOLS REQUIRED
• 5 mm Allen Wrench
• 6 mm Allen Wrench
• In-lb Torque Wrench
• Small Flat Bladed Screwdriver
• Wire Stripper
• Electrical Tape
• Heat Gun
• Terminal Removal Tool PF-52576
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 2 of 7
I-19-02-B
VEHICLE CONTROL MODULE (VCM) & CONNECTOR REPLACEMENT
VCM REMOVAL
1. Connect to motorcycle using Digital Wrench and
record Master PIN and key fob number(s).
IMPORTANT
Make sure you accurately record BOTH the Master PIN
and key fob number(s) before disconnecting the VCM.
2. Using a 5 mm Allen Wrench, remove the fastener e
securing the Vehicle Control Module (VCM)
mounting plate to the top of the battery box.
CAUTION
Do not allow the VCM to contact the positive (B+)
terminal or damage to the VCM will result.
3. Lift the VCM mounting plate enough to access the
negative battery terminal.
4. Using a Phillips screwdriver, remove the negative
battery cable fastener, and secure the ground cables
away from the terminal.
5. Disconnect the three multi-plugs from the VCM.
6. Move the VCM forward to disengage the retaining
posts that secure the front of the VCM to the battery
box and remove. Return the VCM to Indian
Motorcycle.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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REPLACING THE VCM CONNECTOR
1. Locate the two electrical tape pieces on the middle
VCM connector. Peel and remove the electrical tape
closest to the connector of the VCM harness as
shown.
2. Raise the white terminal lock into service mode by
inserting a small flat bladed screwdriver through the
access windows in both sides of the outer connector
body. Pry gently upwards to push up both sides of the
white terminal lock.
3. The white terminal lock will come up 3.8 mm and stop
due to retaining tabs on the sides. There may be an
audible click noted.
IMPORTANT
Do not remove the white terminal lock from the outer
connector body.
CAUTION
If the white terminal lock is removed, the terminals can
fall out of position. Avoid excessive movement of the
harness/connector to ensure the terminals stay in their
locations.
4. Using Terminal Removal Tool PF-52576 remove the
Red Wire (Pin 11) from the connector block. Insert
PF-52576 into the small, round release slot of the
associated terminal(s) until it releases the terminal
retainer. Gently pull the wire out of the connector.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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5. Measure and cut approximately two inches from the
end of the Red Wire (Pin 11). Discard the terminal
end of the wire.
MEASUREMENT
2 inches
6. Using a Wire Stripper, remove approximately 1/2
inch of insulation from Red Wire (Pin 11) and the new
terminal wire.
7. Install the solder tube onto the wires.
8. Using a Heat Gun, apply heat to the solder tube until
the tube is properly secured around both ends of the
wire as shown.
9. Insert the Terminal Removal Tool PF-52576 into the
small, round release slot of the associated terminal(s)
until it releases the terminal retainer. Gently pull the
wire out of the connector.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 5 of 7
10. Remove and replace the wires from the old connector
block to the new one. Refer to the CONNECTOR
BLOCK PIN LAYOUT image and table when
replacing the wires. After replacing each wire, listen
for an audible click and gently pull on the wire to
make sure it is secure.
NOTICE
For best results, extract and replace pins from the
connector block one at a time while transferring them
to the new connector block. Leaving the Terminal
Removal Tool PF-52576 in the place of the pin you are
replacing may also help to avoid confusion about what
terminal the wire came out of.
IMPORTANT
The bottom end of the connector pin has a terminal
retainer tab that allows the pin to clip into the terminal
block.
This raised tab must ALWAYS face the outside of the
terminal block when installing the wire into the new
terminal block.
NOTICE
The white terminal lock must stay up at the service
position for all wire replacement. If you are having
problems with the wires not coming out of the terminal
block, double check that the terminal lock is in the
service position.
STOP!
Once all of the pins have been transferred to the new
connector block, place a white piece of paper between
the electrical wires as shown. Take a picture of both
sides of the connector and wires and submit the photos
to the ASK Polaris case.
11. Press down on the white terminal lock to release it
from service mode.
12. Cut a 3 inch strip of electrical tape and wrap around
the harness wires as shown.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 6 of 7
CONNECTOR BLOCK PIN LAYOUT
**Viewed from the back-side of the connector where the wires enter the connector.**
PIN COLOR WIRE
q YELLOW
w GREEN
e PINK
r GREY
t RED
y GREY/BLUE
u GREEN
i ORANGE/WHITE
o RED/WHITE
a NA
s RED
d GREEN/RED
f GREEN
g BROWN
h NA
j NA
k BLACK
l NA
1( NA
2) RED
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 7 of 7
VCM INSTALLATION
1. Connect the three connectors to the NEW VCM.
Listen for an audible click.
2. Connect the negative battery cable and torque
fastener to specification.
TORQUE
Battery Terminal Fastener:
40 in-lbs (5 N·m)
3. Engage the VCM bracket posts fully into the battery
box slots.
CAUTION
Do not allow the VCM to contact the positive (B+)
terminal or damage to the VCM will result.
4. Install the fastener e securing the Vehicle Control
Module (VCM) mounting plate to the top of the
battery box. Torque fastener to specification.
TORQUE
VCM Bracket Fastener:
84 in-lbs (9 N·m)
5. Connect to motorcycle using Digital Wrench and rewrite
the key fob number(s) previously recorded.
IMPORTANT
Make sure Digital Wrench at the most current version
6. Chose the “key fob maintenance” screen and power
the motorcycle off and then back on. If the fob was
programmed properly, the MASTER PIN should now
show when opening “key fob maintenance” again.
7. Perform the Vehicle Controller update.
NOTICE
If a customer had previously entered a personal
security system pin, it will need to be programmed at
this point. Please see Team Tip I-13-09-01 for
instructions.
8. Test ride the motorcycle to ensure proper operation.
9. File a claim for I-19-02-B

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 1 of 12
SAFETY BULLETIN
IND Release Date: May 07, 2019 Communication #: I-19-02-A/B
Model Year(s): 2014
— Confidential and Proprietary —
VERSION: R03 (March 03, 2020)
** Changed from STOP SALE to SAFETY BULLETIN**
IMPORTANT STOP SALE SAFETY NOTICE!
Stop selling affected vehicles immediately until the repair procedure has
been completed on affected units at your dealership. Federal law prohibits the
sale of products subject to a recall. Selling such products could subject the
seller to substantial penalties.
IMPORTANT
If you are working with a printed copy, please verify you have the most current version of this document.
SUBJECT: 2014 INDIAN MOTORCYCLE - FORWARD LIGHTING
PURPOSE
Indian Motorcycle has decided that an electrical defect may exist in 2014 Indian Motorcycles (111 c.i.), resulting in the
unexpected loss of forward lighting. This defect may also cause thermal damage to the Vehicle Control Module (VCM)
and Pin 11 of the center VCM connector.
Indian Motorcycle has released this bulletin with instructions to inspect the VCM connector for damage & reflash the
VCM. If damage to the connector is present, you will need to start an ASK Polaris case for repair instructions and
warranty claim processing.
AFFECTED MODELS
MODEL YEAR MODELS VEHICLE IDENTIFICATION NUMBER
RANGE
2014
Chief Classic
Reference Unit Inquiry on the dealer website
or the Service Communications list on the
STOP site to lookup affected VINs.
Chief Vintage
Chieftain
IMPORTANT
Vehicles that had ISA-19-02 performed as an interim solution are still required to have this updated repair solution
performed. Reference Unit Inquiry to determine if a VIN is affected.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 2 of 12
CUSTOMER NOTIFICATION
Dealers are required to review their sales records and make arrangements with customers for Bulletin completion. In
addition to consumer units, dealers are required to correct any affected units in their inventory. Indian Motorcycle will
be mailing a notification letter to consumers affected by this Bulletin.
WARRANTY CLAIM PARTS INFORMATION
Bulletin parts are excluded from the standard RMA policy and cannot be returned. An Initial Recommended Order
Quantity has not been provided for this bulletin. Service kit 2208321 will be allocated upon Indian Technical Service
review and approval of ASK Polaris case. For more details, refer to University of Polaris training course "Polaris Item
Availability and Daily Ordering" and click on "Bulletin Ordering Training".
VCM CONNECTOR INSPECTION & VCM REFLASH
Bulletin # I-19-02-A
Claim Type SB (Service Bulletin)
Labor Allowance 0.6 hours (36 minutes)
Part Number / Description 0000541 (QTY 1) Bulletin Misc Labor
Parts Availability NA
University of Polaris Training
Required Yes1
1Polaris 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.
NOTICE
Training required for this bulletin is carried forward from the original release in May, 2019. If your dealership
personal is still certified, you will NOT need to retake the training
VCM & CONNECTOR REPLACEMENT
Bulletin # I-19-02-B
Claim Type SB (Service Bulletin)
Labor Allowance 1.0 hours (60 minutes)
Part Number / Description Additional parts and labor required to complete I-19-02-B to be authorized
through an ASK Polaris case.
Parts Availability Available to order when directed by ASK Polaris
ACCESSORY LABOR
Polaris will cover labor for the removal and installation of accessories required to complete the bulletin work. Follow
the steps below to obtain reimbursement.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 3 of 12
1. Start a new Ask Polaris Case, Service &Warranty Question > Authorization Request: In Warranty or Polaris ESC or
Authorization Request: Out of Warranty/Goodwill.
2. Enter your contact information and VIN, along with miles and hours into the applicable fields.
3. Enter Indian Motorcycle® I-19-02, and I-19-02 in the CONCERN and CAUSE fields. In the CORRECTION field, enter
"ACCESSORY REMOVAL AND INSTALLATION".
4. Enter warranty fail codes 127/277/132.
5. Add part 0000541, quantity 1.
6. Attach photos of the vehicle and accessories sufficient to support the labor time requested.
7. Submit the case to Polaris.
COVERAGE PERIOD
Coverage began on March 3rd, 2020. This bulletin has no expiration date.
PARTS RETURN / DISPOSAL INFORMATION
Under no circumstances shall the parts removed 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 communication) is taken out
of circulation and disposed of properly or returned to Polaris (if required).
SPECIAL TOOLS
• US and Canada Dealers: The special tool outlined in Part B of this Bulletin (PF-52576) was direct-shipped to dealers
in February of 2018 for use with I-18-01. If additional or replacement tools are needed, they can be ordered through
Bosch Automotive Service Solutions, by phone at 1-800-345–2233 or on-line via your dealer website at https://
polaris.service-solutions.com/.
• International Dealers: The special tool outlined in this Bulletin (PF-52576) must be ordered through the Bosch
Service Solutions website. File a Part Stock warranty claim for tool reimbursement.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 4 of 12
I-19-02-A VCM PIN INSPECTION & REFLASH
TOOLS REQUIRED
• Digital Wrench w/ SmartLink or MultiLink XP
• 5 mm Allen Wrench
• 6 mm Allen Wrench
• In-lb Torque Wrench
• Phillips Screwdriver
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 5 of 12
I-19-02-A
VEHICLE CONTROL MODULE (VCM) CONNECTOR PIN 11 INSPECTION & VCM REFLASH
VCM CONNECTOR PIN 11 INSPECTION
IMPORTANT
In the event the following inspection does reveal
damage to Pin 11 of the center VCM connector
(harness side), start an ASK Polaris case for further
instruction as outlined in the I-19-02-B section of this
document.
1. Park the motorcycle on a lift table with the wheel
clamped in a wheel vise.
2. Turn the ignition off.
3. Remove Accessory Trunk, if applicable.
• Remove the left and right saddlebags and remove
the trunk lock fastener t from each trunk latch.
• Disconnect the trunk harness multi-plug r.
• Lift the trunk latches e to unlock the trunk from the
mount.
• Lift up on the rear of the trunk rand slide rearward
t to release the trunk from the motorcycle.
4. Pull carefully on the side panels to release the
retaining posts from the in-frame grommets.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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5. Using a 5 mm Allen Wrench, remove the rear seat
fastener w.
6. Using a 6 mm Allen Wrench, remove the two
fasteners q securing the seat to the frame.
7. Lift the rear of the seat and pull rearward to
disengage the front retaining arms from the bracket
behind the fuel tank.
8. Place the seat upside down on a smooth, clean
surface.
9. Find the VCM located on top of the battery box.
10. Disconnect the center connector on the VCM. Locate
Pin 11 of the VCM1 (center) connector and check for
any discoloration.
IMPORTANT
Pay special attention to the white terminal lock plate
during inspection. If damage is present, a dark halo will
be present around pin 11 of the VCM connector. Refer
to the pictures below for examples.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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DAMAGE IS NOT PRESENT DAMAGE IS PRESENT
VCM connector, pin 11 VCM connector, pin 11
Damage = Any sign of heat or thermal damage in or around pin 11 of the center VCM connector (e.g. the dark halo
shown in the right image above).
STOP!
• If damage IS present, take pictures of the damage and proceed to I-19-02-B.
US/CAN: Submit an Ask Polaris Service & Warranty Question> All Vehicle Diagnostic case.
INT’L: Contact your Country Service Department.
• If damage is NOT present, proceed to step 11 to complete I-19-02-A.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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11. Connect the VCM connector back to the VCM. Listen
for an audible click.
12. Install the seat by sliding the seat forward to engage
the retaining arms on the frame into the seat.
13. Loosely install both side seat fasteners q.
14. Loosely install the rear seat fastener w.
15. Torque all three seat fasteners to specification.
TORQUE
Seat Fastener:
84 in-lbs (9 N·m)
16. Install the side panels by aligning the side panel pins
with the in-frame grommets and push inward to
engage.
17. Install Accessory Trunk, if applicable.
CAUTION
Use care when installing the trunk assembly so that no
electrical wires / connectors get pinched.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 9 of 12
• Lift the flap at the rear of the passenger seat pad to
access the vehicle side of the trunk harness
connector and lay harness on fender.
• Slide the trunk forward q onto the mounting
bracket and lower w the rear of the trunk until fully
seated.
• Push the trunk locking levers e down until fully
seated and the trunk is held securely in place.
• Reconnect the trunk harness connector r.
• If applicable, install the mounting fasteners t into
left and right locking levers.
• Install saddlebags, if equipped.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 10 of 12
VCM REFLASH
1. Verify that Digital Wrench version 4.1 Update 2/26/20
or later has been installed on your PC or laptop and
proceed to step 6.
If you do not have Version 4.1 – Update 2/26/20 or
later installed, you must first download it before
proceeding with the reflash.
NOTICE
If you do not have Digital Wrench installed on your
computer, you must first download the Digital Wrench
Base Version Installer (STEP 2).
2. To download Digital Wrench Base Version, go to your
dealer homepage and select Digital Wrench Base
Version Installer from the Service and Warranty
dropdown menu and download.
NOTICE
International Subsidiaries and Distributors use the
Digital Wrench Subscriptions link to purchase and
update your digital wrench software.
3. Once the Base Version is installed, go to your dealer
homepage and select Digital Wrench Updates from
the Service and Warranty dropdown menu.
4. Click on Digital Wrench Version 4.1 Updates.
5. Download and install Digital Wrench Version 4.1
update 2/26/20 or higher.
6. Connect SmartLink / MultiLink XP cables to PC and
vehicle.
7. Open the Digital Wrench program.
8. Select the model year, product line, and vehicle
description by selecting the “Change Vehicle Type”
icon .
9. Select the Special Test Tab q.
10. Select Vehicle Controller Update w.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
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IMPORTANT
Use of Engine Controller Reprogramming instead of
Vehicle Controllers Update will result in loss of stage
calibration.
NOTICE
Digital Wrench will automatically identify current
software levels and determine which modules require
software updates.
IMPORTANT
Make sure the vehicle battery is fully charged or
connected to a battery charger before proceeding.
STAGE CALIBRATION: If a motorcycle is equipped
with an Indian Motorcycle stage calibration, Digital
Wrench will identify and maintain the upgraded
software calibration if Vehicle Controllers Update is
selected.
CAUTION
The VCM update procedure will take you through TWO
separate reprogramming procedures.
• Boot Mode
• Reflash Application
During the reflash process the gauge and all indicators
will power down. Each procedure must be completed in
sequence or the VCM will not function.
11. Follow the on-screen prompts until all control
modules have been updated.
12. Once the flash is complete, hit the continue button
and leave Digital Wrench connected and ignition
powered ON. Do NOT touch the unit for 35 seconds.
13. Power ignition off and wait 130 Seconds.
14. Check / clear any stored fault codes, disconnect
Digital Wrench and test ride the motorcycle.
NOTICE
Following the VCM reflash, some customers may notice
a slight delay in illumination of their fog lights (if
equipped) during vehicle use. This is normal and is
intended to reduce current flow through the VCM
15. File a claim for I-19-02-A
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris 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 Inc.
I-19-02 (R03) © 2020 Polaris Inc. Page 12 of 12
I-19-02-B
IMPORTANT
US/CAN Dealers: Submit an Ask Polaris Service & Warranty Question > Vehicle Diagnostic Question case.
INT’L Dealers: Contact your Country Service Department.
Submit photos of the dark halo present around VCM pin 11 on the white terminal lock plate and wait for
further instructions from Indian Motorcycle Technical Service.
Do not allow the machine to be operated until you have
repaired the machine as directed by Technical
Service.
If damage is present at Pin 11, do not file a warranty
claim for either I-19-02-A OR I-19-02-B until directed by
Indian Motorcycle Technical Service.