NHTSA ID Number: 10187913
Manufacturer Communication Number: I-21-01
TSB/Document Date: 2021-03-02
Summary
Indian
Motorcycle recently found that some 2020-2021 Challenger models could have an improperly routed hand controls wiring harness. In some instances, the harness may not be routed correctly which could possibly lead to harness damage if uncorrected.
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TSB/Document ID: I-21-01
Replacement Service Bulletin Number:
MFR Communication Date: 2021-02-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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SERVICE BULLETIN
Release Date: February 25, 2021
Expiration Date: February 25, 2022
IND
Communication #: I-21-01
Model Year(s): 2020-2021
— Confidential and Proprietary —
VERSION: R01 (February 25, 2021)
IMPORTANT
If you are working with a printed copy, please verify you have the most current version of this document.
SUBJECT: CHALLENGER HAND CONTROLS WIRING HARNESS
PURPOSE
Indian Motorcycle recently found that some 2020-2021 Challenger models could have an improperly routed hand
controls wiring harness. In some instances, the harness may not be routed correctly which could possibly lead to
harness damage if uncorrected.
Indian Motorcycle has released this procedure to inspect the harness, correct the routing, and replace the hand
controls harness as needed.
Refer to the inspection and repair procedure for detailed information.
AFFECTED MODELS
MODEL YEAR
MODELS
VEHICLE IDENTIFICATION NUMBER
RANGE
2020–2021
Reference Unit Inquiry on the dealer website
or the Service Communications list on the
STOP site to lookup affected VINs.
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. 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 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-21-01 (R01)
© 2021 Polaris Inc.
Page 1 of 29
WA R R A N T Y C L A I M 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. 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".
2020–2021 CHALLENGER (HAND CONTROLS HARNESS INSPECTION)
Bulletin #
I-21-01-A
Claim Type
SB (Service Bulletin)
Labor Allowance
0.7 hours (42 minutes)
Part Number / Description
7082510 (QTY 1) Cable Tie with Clip
Parts Availability
Available to order
University of Polaris Video
Training Required
NO
Claim Submission:
• US / Canada Dealers: On DEX, go to Service and Warranty > Warranty Claim and Extended Coverage > Start a
New Warranty Claim. Select Service Bulletin > Enter the VIN and Retrieve Registration. Select I-21-01-A and Send
Claim.
• International Dealers: On iDEX, go to Service and Warranty> Warranty Claims>Start a New Warranty Claim.
Select Service Bulletin> Enter the VIN and Retrieve Registration. Select I-21-01-A and Send Claim
2020–2021 CHALLENGER (HAND CONTROLS HARNESS REPLACEMENT)
Bulletin #
I-21-01-B
Claim Type
SB (Service Bulletin)
Labor Allowance
2.0 hours (120 minutes)
Part Number / Description
7082510 (QTY 1) Cable Tie with Clip
2414193 (QTY 1) Handlebar Harness - 2020 Challenger
2415694 (QTY 1) Handlebar Harness - 2021 Challenger
Parts Availability
Available to order
University of Polaris Video
Training Required
NO
Claim Submission:
• US / Canada Dealers: On DEX, go to Service and Warranty > Warranty Claim and Extended Coverage > Start a
New Warranty Claim. Select Service Bulletin > Enter the VIN and Retrieve Registration. Select I-21-01-B and Send
Claim.
• International Dealers: On iDEX, go to Service and Warranty> Warranty Claims>Start a New Warranty Claim.
Select Service Bulletin> Enter the VIN and Retrieve Registration. Select I-21-01-B and Send Claim
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-21-01 (R01)
© 2021 Polaris Inc.
Page 2 of 29
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 25, 2021. Coverage will expire on February 25, 2022.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 3 of 29
I-20-01-A HARNESS INSPECTION
TOOLS REQUIRED
3. Gently pry along top edge of headlight bezel D with
non-marring pry tool. Pull headlight bezel D down
and out. Carefully set aside.
• 4mm, 6mm Hex
• Body Panel Removal Tool: 5456907 (or equivalent)
• Wire Cutter
• Torque Wrench
O U T E R FA I R I N G R E M O VA L
1. Open storage doors A and pull out storage liners B.
Set liners aside.
4. Remove and keep three screws E from around
headlight bezel as shown.
2. Carefully pry along edge with non-marring pry tool
to disengage speaker grill assemblies C.
NOTICE
Use Special Tool:
Non-marring Pry Tool, P/N 5456907 (or equivalent)
5. Remove and keep two screws F from top outer
corner of storage openings and two screws F from
top center of speaker openings.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 4 of 29
6. Remove one screw G from under edge of each side of
fairing as shown.
7. Pull fairing outward at top to disengage. Pull fairing
out a short distance and disconnect connectors for
headlight H and turn signals J.
8. Carefully pull outer fairing off motorcycle and set
aside.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 5 of 29
HARNESS INSPECTION
1. From the front of the motorcycle, locate the hand
control harness in the fairing.
2. Cut the harness cable tie securing the extra harness
length.
IMPORTANT
Be careful not to cut any electrical wires when removing
cable ties.
3. Unplug handlebar connector 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-21-01 (R01)
© 2021 Polaris Inc.
Page 6 of 29
4. Remove the handlebar harness connector from the
retaining clip securing it to the fairing casting.
5. Inspect the handlebar harness from the front and rear
of the fairing for harness damage or chaffing or
exposed wires along the harness in location as
shown.
HARNESS DAMAGED AND MUST BE REPLACED,
INSTALL EDGE CLIP
NO DAMAGE FOUND TO HARNESS,
INSTALL EDGE CLIP
STOP!
• If damage to the handlebar harness IS NOT found, continue with edge clip installation.
• If damage to the handlebar harness is found, proceed to harness replacement, found in part B of 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-21-01 (R01)
© 2021 Polaris Inc.
Page 7 of 29
E D G E C L I P I N S TA L L AT I O N
3. Install the harness edge clip to the casting as shown.
1. Verify handlebar harness triple clamp cable tie is
present as shown.
2. While holding the harness straight out from the
motorcycle, measure the harness 3 in (7.6 cm) from
the rear of the casting for accurate placement of the
edge clip. At the measured location, install the edge
clip to the harness so that the opening faces the front
of the motorcycle.
4. Route handlebar wiring through fairing in original
routing. Plug in handlebar connector A. Attach the
connector to the retaining clip
IMPORTANT
Listen for audible "click" when pressing into place. Pull
gently on quick connector once seated to ensure a
proper connection has been made.
5. Replace the removed cable tie, securing the any extra
handle bar harness length in the fairing.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 8 of 29
6. Turn handlebar left and right, lock-to-lock, while
observing the harness for any tension or pulling of
the clip from the casting. Determine if any resistance
from wire binding. If resistance is felt or wire
interference is found, verify clip position in step 2.
Check clearances between hand controls and fuel
tank. Adjust height if necessary.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 9 of 29
O U T E R FA I R I N G I N S TA L L AT I O N
1. Lubricate two grommets with soapy water on inside of
fairing.
2. Set outer fairing in place and connect turn signal J
and headlight H wire connectors.
4. Loosely install three screws E around headlight
bezel as shown.
5. Loosely install one screw G into hole under edge of
each side of fairing as shown.
DO NOT torque fasteners at this time.
3. Press fairing into place and at top edge to engage
locating pins.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 10 of 29
6. Loosely install two screws F into top outer corner of
storage openings and two screws F into top center of
speaker openings.
9. Reinstall fairing speaker grills.
10. Reinsert storage liners.
11. Submit a Service Bulletin Warranty Claim for I-21-01A.
DO NOT torque fasteners at this time.
7. Torque all outer fairing screws to specification.
TORQUE
Outer Fairing Screws E, F, G:
36 in-lbs (4 N·m)
8. Carefully reinstall headlight bezel D into outer
fairing opening starting with bottom tab. Press down
on bezel (or use non-marring tool as shown) to insert
upper tabs without damaging finish.
TIP
Use Special Tool:
Non-marring Pry Tool, P/N 5456907 (or equivalent)
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-21-01 (R01)
© 2021 Polaris Inc.
Page 11 of 29
I-21-01-B HARNESS REPLACEMENT
S I D E C O V E R ( U P P E R ) , R E M O VA L
TOOLS REQUIRED
Left Side
• 4mm, 5mm, 6mm Hex
• Remove upper side cover w.
• Body Panel Removal Tool: 5456907
• T20 driver
• Wire Cutter
• Torque Wrench
• 19mm socket
• 9” socket extension
F U E L S Y S T E M D E P R E S S U R I Z AT I O N
IMPORTANT
Fuel lines remain under pressure at all times. Use
caution when disconnecting lines for service. Always
depressurize the fuel system prior to service.
Right Side
• Remove upper side cover w
WARNING
Allow engine and exhaust to cool completely before
disconnecting fuel line or removing tank. Wear eye
protection.
1. Disconnect the fuel pump fuse and crank engine for 5
seconds to release fuel pressure.
2. Wrap a clean shop towel around fuel line fitting q.
3. Squeeze both release buttons (one on each side of
fitting) and hold. Gently slide fitting straight off fuel
rail.
IMPORTANT
Do not use anything other than fingers to remove the
quick connection. The use of tools can damage the
connection.
4. Cover fuel fittings to keep debris out.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 12 of 29
S E AT R E M O VA L
1. Remove seat fastener q.
2. If equipped, disconnect seat electrical connector.
3. Remove the seat backward and up to remove.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 13 of 29
F U E L TA N K R E M O VA L ( 2 0 2 0 )
3. Disconnect the fuel feed line from the fuel rail.
IMPORTANT
WARNING
Allow engine and exhaust to cool completely before
disconnecting fuel line or removing tank. Protect fuel
tank finish when removing, storing, and installing tank.
Do not use anything other than fingers to remove the
quick connection. The use of tools can damage the
connection.
Be prepared to place the fuel tank in a secure location
with a drain pan positioned to catch any fuel that may
leak or drip from disconnected hoses or fittings.
1. If equipped, disconnect vent lines w from the carbon
canister.
4. Disconnect the fuel pump electrical connector w.
2. Remove left side v-cover by removing its fasteners q.
5. Remove the fuel tank fasteners e.
6. Lift rear of tank upward and pull rearward to remove.
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-21-01 (R01)
© 2021 Polaris Inc.
Page 14 of 29
F U E L TA N K R E M O VA L ( 2 0 2 1 )
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