S-05-10 Bulletin.fm - the Polaris International Extranet

TECHNICAL SERVICE BULLETIN
Snowmobile
Date: 09/28/2005
Safety Bulletin
Distribution:
Service Bulletin
Owner / Principle
Bulletin Number: S-05-10
Model Year(s): 2006
Service Alert Fax
Service Manager
Sales Manager
Production Update Kit
Parts Manager
Technicians
This Service Bulletin is located at www.polarisdealers.com
--Confidential and Proprietary--
SUBJECT: 2006 Early Build 900 Fusion / 900 RMK ECU Re-Flash Procedure
URGENT: Polaris requests that this emissions-related procedure be completed by October 10th, 2005 on all listed
units.
PURPOSE:
Polaris Industries has identified a total of 85 2006 900 RMK (Red-166″ models) and 900 Fusion (Red models) early build snowmobiles manufactured between May 20, 2005 and May 23, 2005 that will require an ECU reflash to meet federal emission requirements.
Polaris has identified a total of 74 snowmobile dealerships that are affected by Service Bulletin: S-05-10. These dealerships were faxed a “Stop
Sales Notice” on August 30, 2005. Affected dealerships will receive a Digital Wrench update disk along with a copy of this Service Bulletin in
the mail. Once your dealership updates Digital Wrench, you will be able to perform the re-flash procedure.
The 2006 model-year 900 Cleanfire ECU file sets are now posted on the re-flash authorization website. These file sets (Red, Blue, and Yellow
fuel injectors) are for ALL 2006, stock 900 Cleanfire systems. Please follow the re-flash instructions within this Service Bulletin for the procedure for re-flashing each affected snowmobile’s ECU.
A detailed list of affected model VINs, along with each unit’s fuel injector color codes can be found on page three. It is essential that the software
you download matches the engine size and injector color for the snowmobile. Polaris will not honor your warranty claim if we determine that the
downloaded software does not match the VIN-specific injector color code.
We are currently shipping out Digital Wrench version 2.09, which is required to be installed on your computer in order to perform this
procedure.
AFFECTED MODELS:
Table 1: S-05-10 Affected Models
Model(s) Affected
Model Numbers
2006 900 Fusion - Stock Red Color
S06MP8DSA
2006 900 RMK - 166 Stock Red Color
S06PN8DSA
Serial Number Range
See Page Three
PARTS INFORMATION:
Table 2: S-05-10 Parts Information
PART NUMBER DESRIPTION
N/A - RE-FLASH SOFTWARE
QUANTITY
N/A - ONE RE-FLASH PER AFFECTED UNIT
DIRECT-SHIP FROM POLARIS?
N/A - DOWNLOADED FROM DEALER WEBSITE
TO BE ORDERED BY DEALER?
N/A
AVAILABILITY
CURRENTLY AVAILABLE
The information contained within this bulletin is confidential and protected by U.S. and international copyright laws, and is the property of PolarisIndustries 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. © 2005 Polaris Sales Inc.
WARRANTY CLAIM INFORMATION:
A single group claim may be submitted listing the complete 17-digit VIN for machines WITH THE SAME MODEL NUMBER. File claim type
SB (Service Bulletin). DO NOT ENTER MORE THAN ONE MODEL NUMBER ON A WARRANTY CLAIM.
Table 3: S-05-10 Warranty Claim Information
Service Bulletin #
S-05-10
Claim Type
SB (Service Bulletin)
Labor Allowance
:30 Minutes
Claim Part Numbers
7170107 - QTY. 1 (Completion Decal)
0000700 - QTY. 1 (Yellow Fuel Injectors)
0000701 - QTY. 1 (Blue Fuel Injectors)
Note: None of the affected units covered by this Service Bulletin S-05-10 have Red Injectors
SERVICE BULLETIN COMPLETION DECAL:
Upon completion of this bulletin, fill out and attach a Service Bulletin Completion Decal, PN 7170107, as shown. If you require more decals,
order them through normal Polaris parts ordering channels.
Sincerely,
Karl Iverslie
Manager, Technical Service & Warranty
The information contained within this bulletin is confidential and protected by U.S. and international copyright laws, and is the property of PolarisIndustries 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. © 2005 Polaris Sales Inc.
Affected Model VIN List
The information contained within this bulletin is confidential and protected by U.S. and international copyright laws, and is the property of PolarisIndustries 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. © 2005 Polaris Sales Inc.
Re-Flash Procedure
1.
2.
Open the hood and the handlebar cover.
Locate the four-pin communication connector, three-pin chassis power-up connector and the
two-pin enabler connector.
3.
Connect the ECU power-up tool, PN PS-47296, to the three-pin connector. Connect the ECU
power-up tool to a fully charged 12-volt battery.
4.
Connect the Digital Wrench communication cable to the four-pin communication connector.
Connect the two-pin program enable jumper to the two-pin program enable connector.
Connect the communication cable to the computer nine-pin serial port.
Start the Digital Wrench diagnostic program and verify that the program has a Status of
Connected. Once running, chose: “2006 Fusion/RMK/Switchback CFI”.
5.
6.
7.
Under the “Special Tests” (tab with the Red Toolbox) menu, chose: #2 - “Engine Controller
Re-Programming”.
8. Verify the correct file sets are loaded into Digital Wrench by checking if the 2006 CFI files
are displayed on the right-side of the screen.
9. Select the engine size and color code injector file that matches the engine size and color
coded fuel injectors that are on the snowmobile. You can locate the color code of the
injectors by looking at the color of the band that is on the injector harness.
10. Verify that the Status mode is in “ECU Reprogramming Mode” and then click on the
“Continue” tab.
11. Verify the laptop, ECU power-up and jumper connectors are installed and secured. Click on
the “Continue” tab.
12. Digital Wrench will generate a request code. Write this code, along with the VIN, down on a
piece of paper. You will need to enter the request code, and the VIN number on the
authorization Website in order to generate an authorization code.
13. Access the re-flash authorization Website at www.polarisdealers.com.
The information contained within this bulletin is confidential and protected by U.S. and international copyright laws, and is the property of PolarisIndustries 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. © 2005 Polaris Sales Inc.
14. Click on the “Service and Warranty” drop down menu.
15. Click on the “Re-Flash Authorization” selection.
16. Click on the “Fusion / RMK” selection.
17. Chose the “2006” model year.
18. Chose the correct engine size and injector color file for the snowmobile you are connected
to.
19. Input the request code into the request code box and select the “Authorize” button.
20. Enter the information that is requested (VIN, name, address, zip code).
21. Click the “Continue” button
22. The re-flash authorization Website will generate an authorization number. Write this number
down on a piece of paper.
23. Enter the authorization number in to the box on the ENGINE CONTROLLER REPROGRAMMING screen. Click on the “Continue” tab.
24. Digital Wrench will now re-flash the ECU. DO NOT TOUCH ANY LAPTOP KEY OR
CONNECTOR DURING THIS PROCESS.
25. Disconnect the 2 pin enable jumper from the snowmobile after the reflash procedure has
been completed. Follow the instructions on the Digital Wrench screen.
26. Click on the “Finish” tab.
27. Open the “Display / Enter Customer & Vehicle Information screen. (Tab with a Mechanic
image.)
28. Locate and record the software number. The software number will match the color of the
injector.
YELLOW =4011530
BLUE = 4011531
29. If for any reason the number does not match the injector color that you had selected, you
must start over.
30. Close Digital Wrench and disconnect the communication cable.
31. Disconnect the power to the ECU power up tool, and remove it from the vehicle.
32. Proceed with completing the warranty claim(s).
33. Once the warranty claim has been filed, send an e-mail containing the VIN number, software number and warranty claim number to the
Polaris contact person.
The information contained within this bulletin is confidential and protected by U.S. and international copyright laws, and is the property of PolarisIndustries 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. © 2005 Polaris Sales Inc.