ATV-07-01_A_B REVISED.fm - the Polaris International Extranet
Contents
1. gt PGLARIS TECHNICAL SERVICE BULLETIN The Way Out ATV 07 01A Date May 21 2007 AAI Terrain Vehicle Povas Nyoro Model Years 2006 bf Safety Bulletin _ Service Bulletin L Service Alert Fax _ Production Update Kit Distribution _ Owner Principal _ Service Manager _ Sales Manager _ Parts Manager _ Technicians This Service Bulletin is located at www polarisdealers com Confidential and Proprietary SUBJECT REVISED 2006 HAWKEYE 2x4 4x4 Intl Front Bearing Carrier Replacement and Steering Post Support Bracket Installation PURPOSE Service Bulletin ATV 07 01A Affects all units produced prior to January 23 2006 These ATVs need to have both the Front Bearing Carrier Replacement and Steering Post Support Bracket Installation performed ATVs affected by this Safety Bulletin have front bearing carrier castings which may have been produced with an insufficient amount of material thickness in the area where the lower a arm and ball joint attach Failure of this component may lead to loss of steering control resulting in an accident and serious personal injury to the operator Updated bearing carrier assemblies have been developed to address this issue ATVs affected by this Safety Bulletin also have steering posts which may fatigue and break in the area where the handlebar attaches to the steering post Failure of this component may lead to loss of steering control resulting in an accident and s2. ATV securely with both front bo tires off the ground Remove both front wheels Front Wheel Nuts 4 Remove both front calipers from the bearing carrier housing Bearing Carriers 5 Remove both front hubs 2x4 ONLY Remove the splined shafts Brake from the bearing carrier assembly at this time Caliper 6 Remove both tie rod ends from the bearing carrier assembly rake Caliper 7 Completely remove the cotter pins pinch bolts and nuts that hold each A arm ball joint to the bearing carrier assembly Tie Rod End 8 Remove the A arm ball joint from each bearing carrier assembly Fastener 4x4 ONLY Remove the CV splined shafts from the bearing carrier Bearing during A arm removal at this time Carrier 9 Remove the fasteners that attach the bearing carriers to the strut housings and remove the bearing carrier assemblies from the vehicle Ball Joint The information contained within this Bulletin is confidential and protected by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Polaris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 3 of 6 IMPORTANT Save all removed warranty parts for recall in accordance with warranty guidelines INSTALLATION 10 Install a new LH Front Beari
3. cted by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Polaris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 6 of 6
4. erious personal injury to the operator A Support Bracket Kit has been developed to address this issue Service Bulletin ATV 07 01B Affects all units produced from January 23 2006 through January 30 2006 These ATVs only require the Front Bearing Carrier Replacement to be performed ATVs affected by this Safety Bulletin have front bearing carrier castings which may have been produced with an insufficient amount of material thickness in the area where the lower a arm and ball joint attach Failure of this component can lead to loss of steering control resulting in an accident and serious personal injury to the operator Updated bearing carrier assemblies have been developed to address this issue AFFECTED MODELS ATV 07 01A Front Bearing Carrier Replacement Steering Post Support Bracket Installation Model Year Model Numbers Models Vehicle Identification Number Range AO6LB27AA Hawkeye 2x4 All VINs produced PRIOR to January 23 2006 A06LD27AA AB AC Hawkeye 4x4 AO6LB27FA Hawkeye 2x4 Intl Reference Unit Inquiry on the dealer website to lookup AO6LD27FB Hawkeye 4x4 Intl affected ATV VINs AFFECTED MODELS ATV 07 01B Front Bearing Carrier Replacement ONLY Model Year Model Numbers Models Vehicle Identification Number Range AO6LB27AA Hawkeye 2x4 All VINs produced from January 23 2006 through A06LD27AA AB AC Hawkeye 4x4 January 30 2006 AO6LB27FA Hawkeye 2x4 Intl Reference Unit Inquiry on the dealer website to
5. laris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 5 of 6 Dear Polaris ATV Owner In cooperation with the U S Consumer Product Safety Commission CPSC Polaris Industries Inc is voluntarily recalling all 2006 Hawkeye 2x4 and 4x4 ATVs produced prior to January 30 2006 Our records indicate that you are still the current registered owner of a potentially affected unit This letter is to notify you that Polaris has determined some Model Year 2006 Hawkeye 2x4 and 4x4 ATVs produced prior to January 23 2006 may have been manufactured with steering posts which may fatigue and break in the area where the handlebar attaches to the steering post Failure of this component may lead to loss of steering control resulting in an accident and serious personal injury to the operator Polaris has also determined that some Model Year 2006 Hawkeye 2x4 and 4x4 ATVs produced prior to January 30 2006 may have been manufactured with an insufficient amount of material thickness in the area where the lower a arm and ball joint are attached to the front bearing carrier Failure of this component may lead to loss of steering control resulting in an accident and serious personal injury to the operator It s important to note that units produced from January 23 2006 through January 30 2006 are only affected by the fro
6. lookup AO6LD27FB Hawkeye 4x4 Intl affected ATV VINs The information contained within this Bulletin is confidential and protected by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Polaris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 1 of 6 PARTS INFORMATION ATV 07 01A Steering Post Support Bracket Installation PART NUMBER DESRIPTION 2203644 Steering Post Support Bracket Kit PARTS AVAILABILITY Week of May 28 2007 QUANTITY Per Affected Unit QTY 1 Support Bracket Kit TO BE ORDERED BY DEALER YES REPAIR PROCEDURE ATV 07 01A Steering Post Support Bracket Installation IMPORTANT NOTE Only certified Master Service Dealer MSD Technicians should perform Safety Bulletin repairs REMOVAL 1 Remove the two plastic push rivets from the rear portion of the instrument pod 2 Remove the two screws that attach the pod support mounts to the pod mounting bracket and set the instrument pod off to the side 3 Remove the four fasteners retaining the upper handlebar block INSTALLATION Revised 4 Assemble the steering support bracket and components according to the instructions in Kit PN 2203644 Torque all fasteners to i specification i2 ft lbs i6 Nm WA 5 Install the two screw
7. ng Carrier Assembly PN 1521236 and Beating RH Front Bearing Carrier Assembly PN 1521237 onto their Carrier corresponding strut housings 11 Install the bearing carrier fasteners through the strut and carrier and torque to 40 ft Ibs 54 Nm 12 Install the A arm ball joints previously removed into the bearing carrier pinch bolt area 4x4 ONLY Install the CV splined shafts into the bearing carrier prior to ball joint installation 54 Nm Verify that the A arm ball joints are fully inserted to allow pinch bolt installation Bearing 20 ft Ibs Carrier i 27 Nm 13 Install the pinch bolts PN 7518698 and nuts PN 7547317 that hold by the A arm ball joints to the bearing carrier assemblies Install pinch Sai Cotter bolts with the bolt head at the front of the machine and the nut at the H B Pin rear Torque to 20 ft Ibs 27 Nm Install the cotter pins PN 7661203 and bend the ends to secure them Ball Joint 14 Install the tie rod ends onto the carrier housing and torque to 40 ft Ibs 54 Nm Bearing Carriers 15 Install both front hubs 2x4 ONLY Install the splined shafts into the bearing carrier assembly at this time Install the washers and hubs Brake nuts and tighten as securely as possible Caliper 16 Install both front calipers and torque the fasteners to 22 ft Ibs 30 Nm Caliper 17 Install the front wheels and tighten as securely as possible Lower ae 22 ft Ibs ATV to ground at this time for final to
8. nt bearing carrier issue DO NOT OPERATE YOUR ATV UNTIL THIS SAFETY BULLETIN HAS BEEN COMPLETED Your authorized Polaris ATV dealer has been issued Safety Bulletins AT V 07 01A and ATV 07 01B Safety Bulletin ATV 07 O1A instructs your dealer to install a steering post support bracket kit and to replace the front bearing carrier assemblies Safety Bulletin ATV 07 01B instructs your dealer to only replace the front bearing carrier assemblies These Safety Bulletins apply even if a front bearing carrier assembly has been previously replaced on an affected unit Please contact an authorized Polaris ATV dealer immedi ately to arrange a time to have the repair s performed to your ATV The parts required to repair your ATV will be available the week of May 28 2007 This work will be performed at no charge to you This notice was mailed to you according to our most current registration information While your Polaris ATV dealer is in the best position to answer your questions if you have any questions your dealer cannot address you may call our Customer Service Depart ment at 1 888 704 5290 If you need assistance contacting a Polaris Dealer please call 1 800 POLARIS or visit the Polaris web site at www polarisindus tries com We apologize for any inconvenience this has caused you pel Manager Service Dealer Development amp Warranty Sincerely K Laurie Rengel The information contained within this Bulletin is confidential and prote
9. possible return to the Warranty Department ATV 07 01A Front Bearing Carrier Replacement and Steering Post Support Bracket Installation Service Bulletin ATV 07 01A Claim Type SB Service Bulletin Labor Allowance 2 0 Hr 120 minutes Claim Part Numbers N A Auto Process Bulletin ATV 07 01B Front Bearing Carrier Replacement ONLY Service Bulletin ATV 07 01B Claim Type SB Service Bulletin Labor Allowance 1 5 Hr 90 minutes Claim Part Numbers N A Auto Process Bulletin SERVICE BULLETIN COMPLETION DECAL A Service Bulletin Completion Decal must be completed for this bulletin repair Place the decal on the unit as shown If you require more decals order them through normal Polaris parts ordering channels Place Decal Here f CUSTOMER NOTIFICATION Consumers with an affected unit should stop riding immediately and have this Safety Bulletin performed Polaris will inform all registered consumers in North America with affected ATVs by mail A copy of the customer letter can be found on page 6 In addition to consumer machines dealers are required to correct any affected machines in their inventory Sincerely Laurie Rengel Manager Service Dealer Development and Warranty April 27 2007 The information contained within this Bulletin is confidential and protected by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Po
10. rque 30 Nm 18 Torque hub nuts to 80 ft Ibs 109 Nm Install the cotter pins and Cotter Pin bend ends to secure them Front Hub CX a es lL oP Wa o 80 ft Ibs 20 Check vehicle for proper wheel alignment and adjust if required gt S N 108 Nm Refer to Hawkeye Service Manual Chapter 2 19 Torque the wheel fasteners to 27 ft Ibs 37 Nm for Polaris steel wheels or 90 ft Ibs 122 Nm for Polaris aluminum wheels Note Non O E M rims follow rim manufacturer s specifications Front Steel 27 ft Ibs 37 Nm Wheel IMPORTANT Test drive unit at slow speeds and re verify the torque Alum 90 ft Ibs 122 Nm of all fasteners before putting vehicle back into service The information contained within this Bulletin is confidential and protected by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Polaris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 4 of 6 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 Removed components are to be retained according to the Polaris Warranty Policy for
11. s that attach the pod support mounts to the pod mounting bracket 6 Install the two plastic push rivets into the rear portion of the instrument pod IMPORTANT Test drive unit at slow speeds and re verify the torque of all fasteners before putting vehicle back into service The information contained within this Bulletin is confidential and protected by U S and international copyright laws and is the property of Polaris Sales Inc This Bulletin is provided for the sole use of authorized Polaris dealers and distributors This Bulletin is not to be distributed duplicated or copied digitally or otherwise without the written consent of Polaris Sales Inc 2007 Polaris Sales Inc Page 2 of 6 PARTS INFORMATION ATV 07 01A or ATV 07 01B Front Bearing Carrier Replacement PART NUMBER DESRIPTION 2203643 Front RH and LH Bearing Carrier Kit PARTS AVAILABILITY Week of May 28 2007 QUANTITY Per Affected Unit QTY 1 Bearing Carrier Kit DIRECT SHIP FROM POLARIS NO TO BE ORDERED BY DEALER REPAIR PROCEDURE ATV 07 01A or ATV 07 01B Front Bearing Carrier Replacement IMPORTANT NOTE Only certified Master Service Dealer MSD Technicians should perform Safety Bulletin repairs Cotter Pin REMOVAL Front Hu 1 Loosen front wheel nuts on both sides N Sy TR 1 ate 2x4 ft A gt Spindle Shaft 2 Remove cotter pins and loosen front hub nuts on both sides VY O 3 S J N Hub Nut 3 Elevate and support the front end of the
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