SERVICE BULLETIN
Release Date: August 14, 2019

LEV

Expiration Date: August 14, 2021

Communication #: L-19-01
Model Year(s): 2016-2018

— Confidential and Proprietary —

VERSION: R01 (August 14, 2019)
IMPORTANT
If you are working with a printed copy, please verify you have the most current version of this document.

SUBJECT: GEM DC/DC CONVERTER
PURPOSE
Some 2016-2018 GEM vehicles built with the 500W DC/DC converter have exhibited premature failure of the component,
including some thermal-related damage. To address this concern, GEM is releasing this Service Bulletin for dealers to
remove 500W converters on all affected units, and replace with a 300W converter.
• If you encounter a vehicle that was upgraded to a 500W converter in the field, and is not showing as affected by this
bulletin, please contact Tech Service to have it added to the bulletin.
• If you have a vehicle affected by this bulletin with a 300W converter, contact Tech Service to close out the bulletin.
IMPORTANT
All other applicable bulletins must be performed prior to completing this bulletin, including L-18-01-B.

AFFECTED MODELS
MODEL YEAR

MODELS

VEHICLE IDENTIFICATION NUMBER
RANGE

E2
2016 - 2018

Reference Unit Inquiry on the dealer website or
the Service Communications list on the STOP
site to lookup affected VINs.

E4
E6
eL XD

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. Polaris will NOT be mailing a
notification letter to consumers affected by this Bulletin.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 1 of 8

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. Use Quantity Ordered to Date and the Open VIN List from the STOP site to
determine an order amount that’s right for your dealership. For more details, refer to University of Polaris training course
"Polaris Item Availability and Daily Ordering" and click on "Bulletin Ordering Training".
2016-2018 GEM E2, E4, E6, EL XD
Bulletin #

L-19-01

Claim Type

SB (Service Bulletin)

Labor Allowance

0.7 Hours (42 Minutes) - DC/DC Converter

Part Number / Description

4013453 - 300W Converter - QTY: 1

Parts Availability

Available to Order

University of Polaris Video Training
Required

NO

INVENTORY / STOCK PART CLAIMS
Dealers should review their service parts inventory and ensure the following service parts are NOT used:
• 4015999 - CONVERTER-48VDC/12VDC,500W
• 2413415 - ASM-HARNESS,DC/DC,JUMPER [USE W/500W CONVERTER]
NOTICE
To remove these service parts from circulation, file a parts stock claim as directed below.
Use the following process for filing a PART STOCK warranty claim for any of the parts listed above.
1. Start a new Part Stock warranty claim.
2. Select Product Line: LEV
3. Enter today’s date into the Date Failed and Date Repair information fields.
4. Enter L-19-01 into the CONCERN field.
5. Enter L-19-01 into the CAUSE field.
6. Enter L-19-01 into the CORRECTION field.
7. Enter the part number and quantity.
8. Enter warranty fail codes: 127 / 438 / 132
9. Validate the parts.
10. Save and submit the claim to Polaris.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 2 of 8

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.
For accessory removal and installation up to 30 minutes of labor:
Enter the actual labor time for the removal and installation into the Accessory R&R Min Field on the bulletin claim.
For accessory removal and installation over 30 minutes of labor:
1. Start a new Ask Polaris Case, Service &Warranty Question > Authorization: Non-Cosmetic & Polaris ESC or
Authorization: Out of Warranty.
2. Enter your contact information and VIN, along with miles and hours into the applicable fields.
3. Enter L-19-01 in the CONCERN and CAUSE fields. In the CORRECTION field, enter "ACCESSORY REMOVAL AND
INSTALLATION".
4. Enter warranty fail codes 127 / 438 / 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.

BULLETIN CONTACT LIST & SCHEDULING TOOL
A scheduling tool is available for dealers to keep a record of customers contacted and scheduled for this bulletin. This
optional tool provides visibility for your dealership and will be helpful to track the status of scheduled service. For more
information, log in to http://www.universityofpolaris.com.

COVERAGE PERIOD
Coverage will begin on 8/14/19. Coverage will expire on 8/14/21.

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).

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. This
feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if
viewing this document electronically.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 3 of 8

REPAIR PROCEDURE
TOOLS REQUIRED
• Multi-Function Pliers

• T-25, T-30 Torx Driver

• Side Cutters

• Torque Wrench

• 8 mm, 10 mm, 13 mm socket/ratchet

REPAIR PROCEDURE
NOTICE
This procedure was written for a vehicle that has all other
applicable bulletins completed. The vehicle must be
equipped with an auxiliary battery before proceeding.

4. Remove two T-30 Torx screws w and eight push-rivets
q. Remove the front fascia.

DC/DC CONVERTER REMOVAL
1. Park vehicle on a flat, level surface and turn key switch
to the OFF position.
2. Remove two hood screws located under the charge
port.

5. Disconnect power at service disconnect, and slide the
main harness side of the service disconnect downward
e to remove it from its mounting clip.

3. Keeping the hood parallel with the ground, pull the hood
forward to release it from the grommets. Carefully lift the
hood away from the vehicle.

CAUTION
Failure to disconnect the service disconnect plug may
result in electrical short damage to the vehicle electrical
systems.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 4 of 8

6. Disconnect charger connections.

8. Remove main negative cable and battery temp sensor
r from the battery pack with a 13mm socket/ratchet,
isolate cable and sensor, and retain hardware.
NOTICE
Li-ion battery packs do not have a temp sensor at this
terminal.

NOTICE
Vehicle shown is equipped with a 6kW fast charger setup.
There are also standard charger and 3kW fast charger
options.
7. Remove fasteners and remove the rear deck.
9. Some vehicles equipped with lithium-ion batteries will
have the auxiliary battery in the rear. For these vehicles:
Remove the 50-amp inline fuse t on the red wire to
disconnect power from the auxiliary battery.
WARNING
Improperly or not disconnecting the battery cables can
result in an electric shock when working on electrical
components.
10. Vehicles with the auxiliary battery under the dash:
Remove six push darts y from upper dash and two in
the glovebox. Retain push darts.

NOTICE
Refer to the service manual for accessory removal.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 5 of 8

11. Lift upper dash to access and disconnect electrical
connectors. Remove dash from vehicle.

14. Remove top two bolts i from the electrical mounting
bracket and loosen the bottom two bolts o.

12. Disconnect positive (+) battery cable u from the
auxiliary battery under the dash.

IMPORTANT
Do not fully remove two lower bolts.
15. Allow electrical mounting bracket to tilt forward,
providing access to electrical connections.
16. Disconnect electrical connection from the DC/DC
converter a.

WARNING
Improperly or not disconnecting the battery cables can
result in an electric shock when working on electrical
components.
13. Remove seven push-rivets from controller cover. Set
cover aside.

17. Vehicles with a 500W converter will have a short
adapter harness between the converter and its
connector on the front harness. Disconnect and discard
the adapter harness.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 6 of 8

18. Remove DC/DC mounting fasteners on right side,
loosen the two left fasteners, slide the converter to the
right and remove 500W DC/DC converter s. Discard
converter, retain hardware.

3. Connect electrical connection w to the DC/DC
converter.

4. Install top bolts into mounting bracket e tighten bottom
bolts r. Torque all four bolts.

DC/DC CONVERTER INSTALLATION

TORQUE

1. Install 300W DC/DC Converter PN: 4013453q by
sliding it into the two left fasteners and align the right
two mounting holes.

Electrical Mounting Bracket Bolts:
8 ft-lbs (11Nm)
IMPORTANT
Before installing the electrical mounting bracket ensure
the cables on the contactor (attached to bottom side of
bracket) have not loosened. Verify torque.
TORQUE
Contactor Nut:
50 in-lbs (5.6 Nm)

2. Install two - 10mm DC/DC mounting fasteners and
torque all four fasteners to specification.
TORQUE
DC/DC Converter Mounting Fasteners:
8 ft-lbs (11 Nm)

5. Reinstall motor controller cover and seven push-rivets.
6. Install service disconnect onto the electrical mounting
bracket.
IMPORTANT
Do not reconnect service disconnect at this time.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 7 of 8

7. Reinstall main battery pack negative using original
hardware.
NOTICE
Reinstall the battery temp sensor for lead acid battery
packs.
WARNING
Improperly connecting the battery cables can result in an
electric shock when working on electrical components.
TORQUE
Battery Terminal Fasteners:
8 ft-lbs (11 Nm)
8. Depending on vehicle’s setup, reinstall 50-amp fuse, or
connect auxiliary battery negative under the dash.
TORQUE
Auxiliary Battery Terminal:
60 in-lbs (7 Nm)
9. Reconnect service disconnect.
10. Using a voltmeter, do a static voltage reading of the
Auxiliary Battery. Voltmeter should read 12-13v.
11. Turn the key switch on, and check the voltage of the
Auxiliary Battery again. There should be a rise in
voltage with the voltmeter reading ~1v higher than the
static reading.
NOTICE
If you are not seeing the correct voltages when testing the
Auxiliary Battery refer to the Service Manual, or contact
Polaris Tech Service for assistance.
12. Turn key switch off.
13. Reinstall rear deck, and any accessories that may have
been installed.
14. Reinstall any dash switches and install upper dash with
original push rivets.
15. Reconnect charger connections.
16. Turn key switch on and ensure lights, turn signals,
wipers and drive modes all function.
17. Reinstall front fascia with original push darts and torx
screws.
18. Install hood and two thumb screws.
19. File bulletin L-19-01.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries. 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.
L-19-01 (R01)

© 2019 Polaris Industries Inc.

Page 8 of 8