I-19-03 - Gear Position Switch - 2014-2019 Indian Chief, Chieftain, Roadmaster, & Springfield Motorcycles

October 29, 2019 NHTSA CAMPAIGN NUMBER: 19V776000

Gear Position Display May Be Inaccurate

If the transmission is not in neutral when the motorcycle is started, the motorcycle may move unexpectedly, increasing the risk of a crash.

 

NHTSA Campaign Number: 19V776

Manufacturer Indian Motorcycle Company

Components POWER TRAIN, ELECTRICAL SYSTEM

Potential Number of Units Affected 52,745

 

Summary

Indian Motorcycle Company (Indian) is recalling certain 2014-2019 Chief, Chieftain, Roadmaster, and Springfield motorcycles. The gear position switch contacts may oxidize, causing the gear position display to inaccurately show that the motorcycle is in neutral when it is actually in gear.

 

Remedy

Indian will notify owners, and as an interim repair, dealers will clean the gear position switch. The switch will be replaced, once parts are available, currently expected to be in the first few months of 2020. These repairs will be performed free of charge. Interim letters notifying owners of the safety risk will be mailed November 19, 2019. Owners may contact Indian customer service at 1-877-204-3697. Indian's number for this recall is I-19-03.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Indian Motorcycle Recalls


SUBJECT: 2014–2019 INDIAN MOTORCYCLE (111 C.I.) GEAR POSITION SWITCH PURPOSE

Indian Motorcycle has determined the gear position switch used on 2014-2019 (111 c.i.) motorcycles may provide an inaccurate signal, which can lead to an incorrect gear being displayed. Oxidation on the contacts of the gear position switch may cause a change in resistance values resulting in the rider display indicating an incorrect gear. Incorrect gear indication during start-up can increase the risk of a crash.

Indian Motorcycle has released this Safety Bulletin, as an interim action, with instructions to inspect and clean the gear position switch on all 2014–2019 (111 c.i.) motorcycles in inventory. We are targeting a resolution by Spring 2020, at that time, a new communication will be released with additional information. In the interim, the gear position switch inspection and cleaning must be performed before any 2014–2019 Indian Motorcycle (111 c.i.) models can be retailed.

 

AFFECTED MODELS

MODEL YEAR MODELS VEHICLE IDENTIFICATION NUMBER RANGE
2014-2019 Chief, Chief Classic, Chief Dark Horse, Chief Vintage Reference Unit Inquiry on the dealer website or the Service Bulletin list on the STOP site to lookup affected VINs.
Springfield, Springfield Dark Horse
Chieftain, Chieftain Classic, Chieftain Dark Horse, Chieftain Limited, Chieftain Elite
Roadmaster, Roadmaster Classic, Roadmaster Elite

 

CUSTOMER NOTIFICATION

Indian Motorcycle will notify consumers by mail no later than 12/28/2019 to inform them of the concern and repair timeline. Consumers will also be reminded of the correct vehicle starting technique. If a gear position concern is identified, or the consumer does not feel comfortable riding their motorcycle, they will be asked to contact an authorized Indian Motorcycle Dealer for further instruction. Indian Motorcycle has also released an interim field communication ISA-19–03 to manage isolated cases mentioned above and consumer concerns regarding the gear position switch.

 

TOOLS REQUIRED

  • Small Flat-Blade Screwdriver
  • 5mm, 6mm, 8mm allen socket
  • 1/4” drive, 6” socket extension
  • 7mm socket
  • Short (stub-nosed) 5mm allen wrench
  • Zip-Tie
  • Scotch-Brite™ green (600 grit or finer)
  • Torque Wrench
  • Magnet
  • Digital Mulit-Meter

 

GEAR POSITION SWITCH INSPECTION / CLEANING

REMOVAL

1. Park the motorcycle on a lift table with the wheel clamped in a wheel vise.

2. Turn the ignition off.

3. Remove the seat. Disconnect the Negative (-) battery terminal.

4. Remove upper right-hand sidecover.

5. Remove right-hand saddlebag (if equipped).

6. Using a 6mm allen socket, remove right-hand rear tip-over bar (if equipped).

7. Using a 8mm allen socket, remove right-hand passenger footpeg (if equipped).

8. Using a flat-bladed screwdriver, loosen clamps and remove right-hand rear heatshield .

9. Remove right-hand lower sidecover.

10. Remove drive sprocket cover.

IMPORTANT
Use of short (stub-nose) 5mm allen wrench is necessary for bottom two bolts and front bolt.

11. From under the motorcycle, unplug gear position connector.

IMPORTANT
Use a small flat-blade screwdriver to depress the retention feature and release the connector.

12. Remove P-clip osecuring the gear position switch wire.

NOTICE
It can be helpful to use a zip-tie to hold the belt out of the way during this step.
IMPORTANT
Use of 1/4" drive 6” extension, 6mm allen socket is necessary for screw removal.

13. Using a 7mm socket, remove gear position switch fasteners and switch.

14. Remove shift drum pins and springs.

NOTE
Use magnet to aid in removal and re-installation of pins and springs (assemble spring onto pin).

15. Measure the free length of the shift drum springs. If the measurement is out of specification, the spring must be replaced.

16. Examine pin for excessive wear at contact point. The pin should move freely in shift drum bore and be smooth and rounded at contact point.

IMPORTANT
If the nose of the pin is visibly worn or does not move freely in the drum bore, the pin must be replaced.

 

GEAR POSITION SWITCH CLEANING

Using a Very-Fine abrasive pad, such as Scotch-Brite™ green (600 grit or finer), apply light pressure by hand in a rotary motion to the contact points f on the switch face until they are clean and uniform in color. Use only enough movement to put a light shine on the brass contacts.

CAUTION
Scotch-Brite™ Green (600 grit is the coarsest abrasive that should be used). DO NOT use a power tool or rotary tool to polish.

 

INSTALLATION

1. Install shift drum pins and springs.

2. Install gear position switch. Torque fasteners to specification.

IMPORTANT
Make sure the gear position switch is properly seated before tightening fasteners.
TORQUE
Gear Position Switch Fasteners:
43 in-lbs (5 N·m)

3. Set multi meter to measure resistance (“Ω” Ohms) to test the switch for proper resistance.

4. Connect one meter lead to each of the pins on the switch connector.

5. Watch the resistance readings as the transmission is shifted through each of the 6 gear positions including Neutral. The meter readings should match the resistance specifications given in the following diagram.

IMPORTANT — AUDIT STEP
A secondary dealer representative must verity that the meter readings match the resistance specifications below.

 

GEAR RESISTANCE (OHMS)
MIN NOMINAL MAX
1st 7.107291 7.481359 7.855427
N 39.53571 41.61654 43.69737
2nd 69.51783 73.17666 76.83549
3rd 103.4657 108.9113 114.3569
4th 139.1792 146.5044 153.8296
5th 186.4891 196.3043 206.1196
6th 248.1241 261.1833 274.2424

 

STOP!
  • If resistance values from any gear position DOES NOT show in the specified range, take pictures of the meter readings and start an ASK Polaris case.

US/CAN: Submit an Ask Polaris Service & Warranty Question> All Vehicle Diagnostic case. INT’L: Contact your Country Service Department.

  • If resistance values from all gear positions DOES show in the specified range, proceed to step 6 and complete Indian Motorcycle® I-19-03.

 

6. Install P-clip o and fastener securing the gear Install drive sprocket cover. Torque fasteners to position switch wire. Torque fastener to specification.

TORQUE
P-clip Fastener:

84 in-lbs (9 N·m)

7. From under the motorcycle, plug in the gear position connector.

IMPORTANT
Listen for an audible click to indicate the connection is secure.
IMPORTANT — AUDIT STEP
A secondary dealer representative must verify the connection is secure.

8. If removed, install the O2 sensor p-clip to the top drive sprocket cover fastener.

9. Install drive sprocket cover. Torque fasteners to specification.

NOTICE
When re-installing, bolts must be loosely assembled into the cover before assembling onto motorcycle.
TORQUE
Heat Shield Clamps: 31 in-lbs (4 N·m)

10. Install right-hand rear heatshield. Torque clamps to specification.

TORQUE
Heat Shield Clamps:
31 in-lbs (4 N·m)

11. Install right-hand lower sidecover.

12. Install right-hand passenger footpeg (if equipped). Torque fastener to specification.

TORQUE
Footpeg Fastener:
35 ft-lbs (48 N·m)

13. Install right-hand rear tip-over bar (if equipped). Torque fasteners to specification.

TORQUE
Tip-Over Bar Fasteners:
18 ft-lbs (24 N·m)

14. Install right-hand saddlebag (if equipped).

15. Install upper right-hand sidecover.

16. Connect the negative (-) battery terminal. Install the seat. Torque fasteners to specification.

TORQUE
Battery Terminal Fasteners: 40 in-lbs (5 N·m)
TORQUE
Seat Fasteners (All): 84 in-lbs (9 N·m)

17.Road test the motorcycle to ensure the correct gear position is indicated, in every gear, on the instrument cluster.

18.File a claim for Indian Motorcycle® I-19-03



24 Affected Products

Vehicles

MAKE MODEL YEAR
INDIAN CHIEF 2014-2019
INDIAN CHIEFTAIN 2014-2019
INDIAN ROADMASTER 2014-2019
INDIAN SPRINGFIELD 2014-2019

4 Associated Documents

Miscellaneous Document - 2014–2019 INDIAN MOTORCYCLE (111 C.I.) GEAR POSITION SWITCH PURPOSE

RMISC-19V776-3838.pdf 7230.529KB

Download (PDF, 6.9MB)


Recall Acknowledgement

RCAK-19V776-3830.pdf 244.893KB

Download (PDF, 239KB)


Defect Notice 573 Report

RCLRPT-19V776-9381.PDF 214.208KB

Download (PDF, 209KB)


Remedy Instructions and TSB

RCRIT-19V776-8150.pdf 7236.979KB

Download (PDF, 6.9MB)


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V776&docType=RCL



 


 

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Last update on 2019-11-18 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-11-18 / Affiliate links / Images from Amazon Product Advertising API

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