Polaris Industries Inc.
Product Development Center
7290 Viking Blvd E
Wyoming, MN 55092
T: 651-408-7579
F: 651-408-7605
December 3, 2015
Associate Administrator for Enforcement
National Highway Traffic Safety Administration
1200 New Jersey Avenue, SE
Washington, D.C. 20590
RE:

579.5 Notices, bulletins, customer satisfaction campaigns, consumer advisories, and
other communications for the month of November, 2015.

Manufacturer:
Report Author:
Telephone Number:

Polaris Industries Inc. (Victory Motorcycle Division; Indian Motorcycle
Company; Global Electric Motorcars (GEM), Slingshot)
Don L. Good
651-408-7579

Polaris Industries Inc sent the following 579.5 communications in the month of November, 2015.

Copies of the above are attached to this report.
If you have any questions with this report, please contact me at 651-408-7579.
Thank you,
Signed:
Don L. Good
Sr. Product Safety Specialist
Polaris Industries Inc.

Date: 12-3-2015

Nov 5, 2015

I-15-04
2015-2016

X

IMPORTANT SAFETY NOTICE!
STOP SALE
SUBJECT: 2015-2016 Indian Full Size Motorcycles – Rear Master Cylinder Repair
PURPOSE:
Some 2015-2016 Indian Full-Size motorcycles have been manufactured with a rear brake master cylinder that does
not meet Indian Motorcycle quality standards. In some vehicles, the rear brake master cylinder piston cup may
develop a tear. Motorcycles assembled with an affected master cylinder may experience a loss of fluid pressure to
the rear brake caliper resulting in reduced rear brake performance. This could cause the vehicle operator to lose
control, increasing the risk of a crash.

AFFECTED MODELS:
2015-2016 Indian Chief Classic, Chief Vintage, Chieftain, Roadmaster, and Dark Horse Motorcycles manufactured on
or between 1/2/2015 – 10/23/2015.
Use ‘Unit Inquiry’ or the Service Bulletin VIN Lookup tool on the STOP Site to identify affected vehicles.

WHAT YOUR DEALERSHIP SHOULD DO:
Wholegood Units:
1. STOP ALL SALES of affected units until this Safety Bulletin has been completed. After the bulletin is
completed and a warranty claim has been filed, it is acceptable to resume sales.
2. Review your dealership’s inventory to locate potentially affected models.
a. Go to the STOP Site and click on the ‘Click Here for a List of Your Dealership’s Units with Open
Bulletins / Recalls’ link located in the Search Options menu.
3. Follow the instructions outlined in this Safety Bulletin to replace the affected rear master cylinder piston
assembly using the updated part detailed in this communication.
4. File a warranty claim immediately after completion of this bulletin.

Parts Stock Inventory:
1. Review your dealership’s parts stock inventory to identify any potentially affected master cylinder
assemblies:
 2205153 – KIT-ASM, REAR MC, IND
 2205751 – KIT-ASM, REAR MC, IND, BLK
 2205157 – KIT-PISTON, REAR MC, IND
2. File a Parts Stock claim for any master cylinder assemblies in dealer inventory and return to Indian
Motorcycle.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 1 of 9)

CUSTOMER NOTIFICATION:
A customer notification letter has been sent to all registered owners of motorcycles affected by this Safety Bulletin. In
addition to the notification letter sent by Indian Motorcycle, dealers are required to notify owners of motorcycles sold
by their dealership, and to make arrangements to perform this bulletin immediately.

WARRANTY CLAIM INFORMATION:
A single group claim may be submitted listing the complete (17-digit) Vehicle Identification Number for machines
with the same model number. File claim type: SB (Service Bulletin). DO NOT PUT MORE THAN ONE MODEL
NUMBER ON A CLAIM.
REAR MASTER CYLINDER - REBUILD
SERVICE BULLETIN #

I-15-04

CLAIM TYPE

SB (Service Bulletin)

LABOR ALLOWANCE

36 Minutes (0.6 Hours)

CLAIM PART NUMBERS

N/A – Auto Process Bulletin

PARTS INFORMATION:
REAR MASTER CYLINDER – REBUILD (I-15-04)
PART NUMBER / DESCRIPTION

PARTS AVAILABILITY

7170107 (QTY. 1) – Service Bulletin Completion Decal
2206308 (QTY. 1) – Piston Kit, Rear Master Cylinder*
7556372 (QTY. 2) – Copper Sealing Washer
7661010 (QTY. 1) – Cotter Pin, Push Rod
Available to order
*NOTE: 2206308 will be available 11/9 to order in limited quantities.
Sufficient inventory to fulfill bulletin requirements will be in stock no later
than 11/20/2015.

DIRECT-SHIP FROM POLARIS?

No

TO BE ORDERED BY DEALER?

Yes

PARTS RETURN INFORMATION:
ATTENTION: North American Dealers – All master cylinder pistons affected by this bulletin should to be returned via
the normal warranty parts return system (DO NOT RMA).
Include the Vehicle Identification Number (VIN) and the date code located on bottom of the master cylinder housing
(refer to image below). NOTE: Date code is also pin stamped on the master cylinder housing under the label.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 2 of 9)

Dealers & Distributors: Under no circumstances shall the part removed in this repair be re-used, sold, or repurposed for another application. It is your dealership / distributorship’s responsibility to make sure every part
replaced is taken out of circulation and returned to Indian Motorcycle.
For North American Dealers: Once the warranty claim for each unit has processed, please review the “Check
Returned Parts List” on your dealer website to determine whether or not Indian Motorcycle has asked for the part(s)
to be returned. If the part(s) were not identified as needing to be returned to Indian Motorcycle, please dispose of
the part(s) properly.

SERVICE BULLETIN COMPLETION DECAL:
A Service Bulletin Completion Decal must be completed for this
bulletin repair. Place the decal on the unit as shown (inside left side
cover). If you require more decals, order them through normal
parts ordering channels.
Sincerely,

Doug Koch,
Technical Service and Warranty Manager

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 3 of 9)

REAR MASTER CYLINDER PISTON REPLACEMENT:
IMPORTANT: Brake fluid and brake cleaners will damage paint, plastics and some rubber compounds. Cover or
remove plastic and painted parts before working on the brake system. If brake fluid is spilled on cosmetic surfaces,
immediately rinse the area with a mild solution of soap and water until all traces of brake fluid are removed. Make
sure the master cylinder reservoir being worked on is level before removing the cap.
REAR MASTER CYLINDER DISASSEMBLY/INSPECTION
1. Place the motorcycle in an upright position with the
front wheel clamped in a wheel vise.
2. Remove the brake line banjo bolt ①. Remove
sealing washers and discard. To prevent loss of
brake fluid suspend the open end of the brake line
upright or place in a container of clean brake fluid
while servicing the master cylinder. NOTE: Prevent
brake fluid from contacting cosmetic surfaces.

3. Remove cotter pin ② from push rod pin and remove
washer.

4. Remove jam nut ③ and remove the master cylinder
from the floorboard support. NOTE: Use caution to
ensure wrench does not contact the master cylinder
reservoir.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 4 of 9)

5. Place rear brake master cylinder on a clean work
surface. IMPORTANT: Maintain cleanliness of
work surface and master cylinder components.
Any debris or fluid could damage master cylinder
components.
6. Clean rear brake master cylinder external
surfaces and remove cover screws, cover and
cover seal
7. Using a suitable fluid recovery container, pour
out the brake fluid in the master cylinder
reservoir and dispose of brake fluid properly.
8. Remove external snap ring ④, washer ⑤, dust
boot ⑥, spring retainer ⑦ and return spring ⑧.
NOTE: Spring retainer and return spring are
typically retained in the dust boot.

9. Remove and discard internal snap ring ⑨.
Remove pushrod/retainer bushing assembly ⑩
and piston assembly ⑪.

10. Remove piston return spring ⑫ from piston
assembly ⑪. NOTE: Retain and tag piston for
warranty parts return.
11. Clean all internal parts with Indian Motorcycle
DOT 4 brake fluid or isopropyl alcohol from a
sealed container.
12. Inspect cylinder bore and chamfer on front of the
bore for corrosion, scratches, scoring or pitting.
Replace master cylinder if any of these conditions
are evident.
13. Use compressed air to clear fluid holes and
passages to verify they are clean and
unobstructed.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 5 of 9)

REAR MASTER CYLINDER ASSEMBLY:
1. Insert original piston return spring ① in the NEW
piston assembly ②.
2. Lubricate piston assembly and master cylinder bore
with clean Indian Motorcycle DOT 4 brake fluid.

3. Align the piston assembly ③ with the master
cylinder bore ④.

4. Partially insert the piston assembly into the master
cylinder bore taking care so the spring does not
scratch or damage the bore. NOTE: Do not fold or
damage the piston seals and cup when inserting
piston.
5. Use a flashlight to view the spring end through the
fluid outlet port to guide the spring end into the
master cylinder counter bore (refer to image at
right).

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 6 of 9)

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8. Insert the pushrod ⑥ retainer bushing assembly ⑤
and depress both into master cylinder bore deep
enough until snap ring groove is visible above
retainer bushing. Install NEW snap ring ⑦ with
square edge facing out in snap ring groove. NOTE:
Verify snap ring is fully seated in groove.

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6. Verify the spring is seated correctly in the master
cylinder counter bore before fully seating the piston
in the master cylinder bore. NOTE: Spring is
installed incorrectly if end is visible through the
outlet port (refer to image at right).
7. If spring is seated correctly proceed to step 8. If
spring is not seated correctly remove piston
assembly and repeat steps 3-7.

U
.S

.C

9. Assemble return spring ⑧, spring retainer ⑨, dust
boot (with drain hole facing down) ⑩, and washer
⑪ on the pushrod. Depress return spring, cup, dust
boot and washer down the pushrod to expose the
snap ring groove...

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 7 of 9)

10. Install the snap ring ⑫ in the pushrod groove with
the square edge facing away from master cylinder.
NOTE: Verify dust boot is seated in groove on back of
master cylinder housing

REAR MASTER CYLINDER INSTALLATION:
1. Install the master cylinder to floorboard support and
torque the jam nut ① to specification.
TORQUE:
Master Cylinder Jam Nut: 35 ft-lbs (47.5 Nm)

2. Install a NEW sealing washer ② on each side of the
banjo fitting and torque the banjo bolt ③ to
specification. NOTE: Do not reuse brake sealing
washers.
TORQUE:
Brake Line Banjo Bolt: 18 ft-lbs (24.4 Nm)

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 8 of 9)

3. Assemble the pushrod onto the brake pedal pin.
Install washer ④ and a NEW cotter pin ⑤.

4. Bleed the rear brake system as outlined in Chapter
14 of the 2014-2016 Indian Motorcycle (Full-Size)
Service Manual (PN 9925933).
5. Top up the brake fluid as necessary and install the
reservoir cover. Torque screws ⑥ to specification.
TORQUE:
M/C Reservoir Cover Screws: 13 in-lbs (1.5 Nm)
6. Test ride the motorcycle to verify proper brake
operation and pedal feel.
7. Include the VIN and master cylinder date code on a
tag attached to the original master cylinder piston for
warranty return (refer to PARTS RETURN
INFORMATION).
8. File a warranty claim for I-15-04.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Indian Motorcycle International, LLC. This Service Bulletin is
provided for the sole use of authorized Indian Motorcycle dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of
Indian Motorcycle International, LLC
© 2015 Indian Motorcycle International, LLC (Page 9 of 9)

IMPORTANT SAFETY RECALL

Indian Motorcycle Company
P.O. Box 47700
Medina, MN 55340-9960

This notice applies to your vehicle
VIN:
Recall Campaign: 15V-721
Subject: 2015-2016 Indian Full Size Motorcycles
Rear Master Cylinder Repair

PLEASE READ IMMEDIATELY

Dear Indian Motorcycle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Indian Motorcycle
has decided that a defect which relates to motor vehicle safety exists in certain 2015-2016 Indian Full Size motorcycles. Our records
indicate that you have purchased a potentially affected vehicle.

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The reason for this recall:
Indian Motorcycle has decided that some 2015-2016 Indian Full Size motorcycles may have been manufactured with a rear brake
master cylinder that does not meet Indian Motorcycle quality standards. In some vehicles, the primary cup seal located in the rear master
cylinder may not fully seal into the master cylinder bore. Motorcycles assembled with an affected master cylinder may experience a loss of
pressure to the rear brake caliper resulting in rear brake failure. This could cause the vehicle operator to lose control, increasing the risk
of a vehicle crash.

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What Indian Motorcycle and your dealer will do:
Indian Motorcycle will issue a Safety Recall Bulletin to all Indian Motorcycle dealers, with instructions required to replace the rear brake
master cylinder piston and seals. Repairs will be made by any authorized Indian Motorcycle dealer at no cost to you. The actual master
cylinder repair should take about one hour to perform; however, it may take longer due to service scheduling requirements.
What you should do:
Contact your authorized Indian Motorcycle dealer to schedule an appointment to have the bulletin repair performed. Do not attempt
repairs yourself. Repairs must be done only by an authorized Indian Motorcycle dealer.

2.

Press downward on the rear brake pedal. It should move freely and smoothly. The pedal should feel firm and continue to feel
firm until released.
Release the pedal. It should return to its rest position quickly when released.

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Pre-Ride Inspection
Before riding your motorcycle to an authorized dealer to have the bulletin procedure(s) completed, please perform the following pre-ride
brake inspection prior to riding your motorcycle to the dealership:

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If the rear brake pedal fails to perform as stated or travels too far before beginning to engage the brake do not ride your motorcycle
before the repairs are made. Work with your Indian Motorcycle dealer to arrange transportation.

U
.S

If you have questions or if you need more information:
While your Indian Motorcycle dealer is in the best position to answer your questions, if you have any questions that your dealer cannot
address, if you are having difficulty obtaining the recall repair outlined in this letter, or if you need assistance finding an Indian
Motorcycle dealer, please visit the web site at www.indianmotorcycle.com or contact our Indian Motorcycle Consumer Service
Department by calling 1-877-204-3697.
This notice was mailed to you according to our most current registration information. If you no longer own your Indian motorcycle,
please contact your local Indian Motorcycle dealer to have the ownership information changed. The Indian Motorcycle Consumer
Service Department cannot change ownership information without identification. Federal law requires that any vehicle lessor receiving
this recall notice must forward a copy of this notice to the lessee within 10 days.
If you have had this repair performed before you received this letter, you may be eligible to receive reimbursement for the cost of
obtaining a pre-notification remedy of the problem associated with this recall. For more information regarding obtaining reimbursement
please contact the Indian Motorcycle Consumer Service Department using the contact information above.
If you believe that Indian Motorcycle has failed to remedy this defect without charge or is unable to do so within a reasonable time, you
may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE.,
Washington, D.C. 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1- 800-424-9153); or on the web go to
http://www.safercar.gov.
Please accept our apologies for any inconvenience this may cause you. Your safety and continued satisfaction with your Indian
Motorcycle is our primary concern. Thank you for your prompt attention to this matter.
Sincerely,
Indian Motorcycle Company

SLI-15-11-01
Nov 19, 2015
SUBJECT: SLINGSHOT – REAR SPROCKET RETAINING NUT RUNNING CHANGE
MODELS: ALL 2015-2016 SLINGSHOT MODELS
The Slingshot Division of Polaris Industries has developed updated rear sprocket retaining nuts and Loctite® on 2016
Slingshot models manufactured after 11/02/2015. The single hex flanged-style nut has been replaced with two hex head
nuts. Loctite® 641 (Yellow) applied to the rear axle splines and threads has been replaced by Loctite® 680 (Green).
Updated rear sprocket retaining nuts and Loctite® should be installed on any vehicles built prior to 11/2/2015 if any of
the following conditions are encountered:
1. A clicking or popping noise from the rear axle area during low speed operation
NOTE: This noise is similar to and may be mistaken for a damaged rear wheel bearing
2. Reduced clamp force on the rear sprocket nut
3. A service procedure requiring removal of the rear sprocket is performed
The Driven Sprocket Replacement procedure in the Slingshot Service Manual has been updated and posted on the
STOP Site for reference, update your manual accordingly. The Polaris Online Electronic Parts Catalog has also been
updated to include the new hardware.

OLD (PN 7547617 – QTY 1)

NEW (PN 7547831 – QTY 2)

TORQUE

TORQUE

250 lb-ft (339 Nm)

Inside Nut: 250 lb-ft (339 Nm)
Outside Nut: 150 lb-ft (203 Nm)

Loctite® 641 (Yellow)

Loctite® 680 (Green)

The information contained within this Team Tip is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. This Team Tip is provided for the sole use
of authorized Polaris dealers and distributors. This Team Tip is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2015 Polaris Industries Inc. (Page 1 of 1)

SLI-15-05
2015-2016

11/24/2015

X

IMPORTANT SAFETY NOTICE!
STOP SALE
SUBJECT: 2015-2016 Slingshot / Slingshot SL – Headlight Jumper Harness Installation
PURPOSE:
Polaris has determined that some Slingshot vehicles were manufactured with a headlight circuit that does not meet
Polaris quality standards. In some vehicles, heat buildup in the engine compartment may cause the headlight circuit relay
to derate below the required current draw of the headlights. In addition, temperatures produced at the fuse box terminal
pin may be higher than desired. The result of such a condition could be a loss of forward lighting function. This could
cause decreased visibility for the vehicle operator, increasing the risk of a vehicle crash.

POTENTIALLY AFFECTED MODELS:
2015-2016 Slingshot and Slingshot SL models manufactured on or before 10/26/2015.
Use ‘Unit Inquiry’ or the Service Bulletin VIN Lookup tool on the STOP Site to identify affected vehicles.

WHAT YOUR DEALERSHIP SHOULD DO:
1. STOP ALL SALES / TEST RIDES / DEMO RIDES until this Safety Bulletin has been completed on affected units.
After the bulletin is completed and a warranty claim has been filed, it is acceptable to resume sales / test rides /
demo rides.
2. Review your dealership’s inventory to locate potentially affected models.
a. Use ‘Unit Inquiry’.
OR
b. Login to the dealer website.
c. Locate the ‘Service and Warranty’ dropdown, click on STOP Site.
d. On the left hand side of the page, under ‘STOP Site Links’, click on ‘Service Bulletins’.
e. Locate the SLI-15-05 link and click on the ‘All VINs’ link located on the right.
f. The ‘All VINs’ page will display all affected VINs within your dealership’s inventory.
3. Perform the headlight jumper harness inspection and installation procedure outlined in this Safety Bulletin on all
affected units.
4. File a warranty claim following completion and attach a bulletin completion decal as shown on page 2 of this
bulletin.

CUSTOMER NOTIFICATION:
A customer notification letter will be sent to all registered owners of affected vehicles. In addition to the notification letter
sent by Polaris, dealers are required to review sales records and contact consumers who have purchased a potentially
affected vehicle. Make arrangements to perform the steps outlined in this Safety Bulletin immediately.

The information contained within this Bulletin is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Industries Inc. This Service Bulletin is provided for the sole
use of authorized Polaris dealers and distributors. This Service Bulletin is not to be distributed, duplicated, or copied, digitally or otherwise, without the written consent of Polaris Industries Inc.
© 2015 Polaris Industries Inc. (Page 1 of 6)

PARTS / WARRANTY CLAIM INFORMATION:
A single group claim may be submitted listing the complete (17 digit) Vehicle Identification Number for machines with the
same model number. File claim type: SB (Service Bulletin). DO NOT PUT MORE THAN ONE MODEL NUMBER ON A
CLAIM.
SERVICE BULLETIN #

SLI-15-05

CLAIM TYPE

SB (Service Bulletin)

LABOR ALLOWANCE

30 Minutes (0.5 Hours)

PART NUMBER / DESCRIPTION

7170107 (QTY.1) – Service Bulletin Completion Decal
2881939 (QTY.1) – Kit-Headlight, Relay Jumper

PARTS AVAILABILITY

Available to order

DIRECT-SHIP FROM POLARIS?

No

TO BE ORDERED BY DEALER?

Yes

PARTS RETURN OR DISPOSAL INFORMATION: