NHTSA ID Number: 10172520
Manufacturer Communication Number: I-20-01-A
TSB/Document Date: 2020-03-16
Summary
Some Indian
Challenger motorcycles may exhibit poor run quality and engine misfire shortly after setup and/or delivery to customer. Indian Motorcycle engineering has released an updated ECU calibration and throttle body inspection procedure to correct this issue on affected motorcycles.
SERVICE BULLETIN
Release Date: February 28, 2020
Expiration Date: February 28, 2021
IND
Communication #: I-20-01-A/B
Model Year(s): 2020
— Confidential and Proprietary —
VERSION: R01 (February 28, 2020)
IMPORTANT
If you are working with a printed copy, please verify you have the most current version of this document.
S U B J E C T : E C U C A L I B R AT I O N R E F L A S H / T H R O T T L E B O D Y I N S P E C T I O N
PURPOSE
Indian Motorcycle Technical Service has received isolated reports of Challenger motorcycles exhibiting poor run
quality and engine misfire shortly after setup and/or delivery to customer. Indian Motorcycle engineering has
released an updated ECU calibration and throttle body inspection procedure to correct this issue on affected
motorcycles.
AFFECTED MODELS
MODEL YEAR
MODELS
VEHICLE IDENTIFICATION NUMBER
RANGE
2020
Reference Unit Inquiry on the dealer website
or the Service Communications list on the
STOP site to lookup affected VINs.
IMPORTANT
This calibration update is pending approval for use on International models. Until that time, 2020 Challenger models,
designated for sale outside of North America, are not eligible to have the calibration update performed.
C U S T O M E R N O T I F I C AT I O N
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
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 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-20-01 (R01)
© 2020 Polaris Inc.
Page 1 of 11
WA R R A N T Y C L A I M PA R T S I N F O R M AT I O N
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. If necessary, parts needed to complete Part B of this bulletin will be
allocated once an ASK Polaris case has been submitted and approved. For more details, refer to University of Polaris
training course "Polaris Item Availability and Daily Ordering" and click on "Bulletin Ordering Training".
ECU REFLASH & THROTTLE BODY INSPECTION
Bulletin #
I-20-01-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 Video
Training Required
NO
THROTTLE BODY REPLACEMENT
Bulletin #
I-20-01-B
Claim Type
SB (Service Bulletin)
Labor Allowance
1.3 hours (78 minutes)
Part Number / Description
Requires authorization through an ASK Polaris case.
Additional parts and labor required to complete I-20-01-B to be authorized
through an ASK Polaris case.
Parts Availability
Available to order when directed by ASK Polaris
University of Polaris Video
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.
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: In Warranty or 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 Indian Motorcycle® I-20-01, and I-20-01 in the CONCERN and CAUSE fields. In the CORRECTION field, enter
"ACCESSORY REMOVAL AND INSTALLATION".
4. Enter warranty fail codes 140/280/137.
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.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 2 of 11
B U L L E T I N C O N TA C T L I S T & S C H E D U L I N G T O O L
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 February 28, 2020. Coverage will expire on February 28, 2021.
UNIVERSITY OF POLARIS TRAINING REQUIREMENT
Each member of your service department team must complete the training on University of Polaris prior to completing
ANY work, or submitting ANY warranty claim for this Bulletin. You must complete the entire course on University of
Polaris in order to get credit.
www.universityofpolaris.com
PA R T S R E T U R N / D I S P O S A L I N F O R M AT I O N
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 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-20-01 (R01)
© 2020 Polaris Inc.
Page 3 of 11
I-20-01-A ECU REFLASH & THROTTLE BODY INSPECTION
TOOLS REQUIRED
• Synchronizing Tool - RMI-TO-007
• Digital Wrench w/ MultiLink XP
• Long Needle Nose Pliers
ECU REPROGRAMMING PROCEDURE
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.
3. Once the Base Version is installed, go to your dealer
homepage and select Digital Wrench Updates from
the Service and Warranty dropdown menu.
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.
4. Click on Digital Wrench Version 4.1 Updates.
5. Download and install Digital Wrench Version 4.1
update 2/26/20 or higher.
NOTICE
International Subsidiaries and Distributors use the
Digital Wrench Subscriptions link to purchase and
update your digital wrench software.
6. Park the motorcycle on a lift table with the wheel
clamped in a wheel vise.
7. Turn the ignition off.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 4 of 11
8. Remove the left-hand side upper cover.
13. Select Engine Controller Reprogramming.
9. Connect MultiLink XP cables to PC and vehicle.
NOTICE
10. Open the Digital Wrench program.
11. Select the model year, product line, and vehicle
description by selecting the “Change Vehicle Type”
icon .
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.
14. Select the applicable reflash from the list.
12. Select the Special Tests tab.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 5 of 11
• For motorcycle with STAGE CAL updates, contact
Indian Motorcycle Technical Service to obtain a
reflash authorization key.
15. Follow the on-screen prompts until all control
modules have been updated.
16. 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.
17. Power ignition off and wait 130 Seconds.
18. Check / clear any stored fault codes, disconnect
Digital Wrench and test ride the 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.
I-20-01 (R01)
© 2020 Polaris Inc.
Page 6 of 11
THROTTLE BODY INSPECTION
5. Turn off the motorcycle.
Indian Motorcycle shipped synchronization gauges to
North America dealers the week of 2/24/2020. Although
the gauge kit is designed for 4 cylinder engines, only
two gauges are to be used for the following procedure.
Indian Motorcycle recommends using two gauges that
are located next to each other.
6. Working from the right-hand side of the motorcycle,
use long needle-nose pliers to remove both purge
lines OR purge line plugs from the throttle body.
1. If gauges do not read zero at atmospheric pressure,
as shown in the picture below, remove the plastic
cover and carefully adjust the adjustment screw until
needles are in the center of the white strip.
• 50 STATE: Remove both purge lines q from the
throttle body.
IMPORTANT
Both gauges must read the same value before use.
2. Un-wrap the flexible lines and cut them about 4
inches from the ends. Assemble each part of the lines
to the plastic needle valve included in the kit. Both
valves should be installed the same distance from
each of the two gauges to ensure pressure pulses are
read the same.
3. Attach short rubber hose/adapter section and 90
degree fitting to the end of the vacuum line that will
be attached to the purge port on the throttle body.
• 49 STATE: Remove the purge line plugs w from the
throttle body.
4. Start the motorcycle and allow the engine to run until
it reaches operating temperature (the cooling fan
turns on).
IMPORTANT
Be careful not to lose the purge line plugs.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 7 of 11
7. Connect both rubber hoses to the throttle body purge
ports using a set of long needle-nose pliers.
IMPORTANT
Be careful not to damage the fuel injector electrical
wires when attaching or removing the rubber hoses.
8. Start the motorcycle and allow the engine to run until
the cooling fan turns on.
STOP!
The engine operating temperature is critical to achieve
accurate readings. Make sure the engine fan has cycled
before testing the throttle body synchronization.
9. Adjust needle valves on both lines to achieve less
than 1 inch Hg fluctuation on the gauge (outer
graduations). Maintain some gauge flutter to ensure
the valve is not closed entirely.
IMPORTANT
Take a picture of the gauge reading
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-20-01 (R01)
© 2020 Polaris Inc.
Page 8 of 11
10. Read both gauges in relation to each other.
Determine the difference in the readings.
EXAMPLE OF A GOOD READING
EXAMPLE OF A BAD READING
STOP!
• If the difference in readings between each side is BELOW 1.5 inches Hg, the throttle body is synchronized. Install
both purge lines / plugs and proceed to STEP 11 to complete I-20-01-A.
• If the difference in readings between each side is AT OR ABOVE 1.5 inches Hg, the throttle body is not synchronized
and must be replaced. Proceed to I-20-01-B
US/CAN: Submit an Ask Polaris Service & Warranty Question> All Vehicle Diagnostic case.
INT’L: Contact your Country Service Department.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 9 of 11
11. Working from the right-hand side of the motorcycle,
use long needle-nose pliers to install both purge
lines OR purge line plugs to the throttle body.
12. Test ride the motorcycle to ensure proper operation.
13. File a claim for I-20-01-A
• 50 STATE: Install both purge lines q to the throttle
body.
• 49 STATE: Install the purge line plugs w to the
throttle body.
IMPORTANT
Be careful not to lose the purge line plugs.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 10 of 11
I-20-01-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 sync gauge reading and wait for further instructions from Indian Motorcycle Technical
Service.
Take a photo of the CV scan code located on the top of the throttle body.
If the sync gauge difference between the two cylinders
is reading at or above 1.5 inches Hg, do not file a
warranty claim for either I-20-01-A OR I-20-01-B until
directed by Indian Motorcycle Technical Service.
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-20-01 (R01)
© 2020 Polaris Inc.
Page 11 of 11
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TSB/Document ID: I-20-01-A
Replacement Service Bulletin Number:
MFR Communication Date: 2020-02-28
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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