SUBJECT: 2007 – 2009 IQ CFI Fuel Hose Routing Inspection / Fuel
Contents
1. Process Bulletin SERVICE BULLETIN COMPLETION DECAL A Service Bulletin Completion Decal must be completed for this Bulletin repair Attach the decal to the airbox assembly If you require more decals order them through normal Polaris parts ordering channels CUSTOMER NOTIFICATION Polaris will mail a notification letter to all customers who purchased an affected snowmobile Sample letter provided on page 4 of this Bulletin In addition to this letter dealers are required to notify owners of affected models and those customers identified as purchasing affected parts and make arrangements to perform this repair Sincerely Laurie Rengel Manager Service Dealer Development and Warranty SAFETY RECALL NOTICE PLEASE READ IMMEDIATELY March xx 2009 Dear Polaris Snowmobile Owner In cooperation with the U S Consumer Product Safety Commission CPSC Polaris Industries Inc is voluntarily recalling all 2007 2008 and 2009 Polaris IQ 600 and 700 IQ CFI Switchback CFI and Touring CFI snowmobiles This letter is to notify you that Polaris Industries Inc has determined the fuel return hose on select 2007 2008 and 2009 600 and 700 IQ CFI Switchback CFI and Touring CFI snowmobiles may be incorrectly located in the P clamp located on the upper LH side of the airbox If located incorrectly the fuel hoses may rub together and wear through possibly creating a fuel leak DO NOT USE YOUR SNOWMOBILE UNTIL DEALER INSPECTION OR REPLACEM2. lt gt POLARIS TECHNICAL SERVICE BULLETIN Date March 31 2009 Sno wmobile minasa T C Safety Bulletin gt Distribution _ Owner Principal Service Manager _ Sales Manager Parts Manager _ Technicians SUBJECT 2007 2009 IQ CFI Fuel Hose Routing Inspection Fuel Hose Replacement PURPOSE Polaris Industries Inc has determined the fuel return hose on select 2007 2008 and 2009 600 and 700 IQ CFI snowmobiles may be incorrectly located within the P clamp located on the upper left hand side of the airbox If located incorrectly as shown in PHOTOS C and D on page two the fuel supply and return hoses may rub together and wear through possibly creating a fuel leak Please follow the INSPECTION and REPAIR procedures as outlined within this Service Bulletin and inspect each affected vehicle and replace the fuel supply hose s if required AFFECTED MODELS Model Year Model Numbers Model Vehicle Identification Number Range SO7PD6HS SO7PD6HE 600 IQ LX CFI SO7PP6HS SO7PP6HSA 600 IQ CFI SO7PP6HSB 2007 SO7PS6HS SO7PS6HSA 600 Switchback CFI SO7PS6HSB SO7PT6HS SQ7PT6HE 600 Touring CFI SO8PD6HS 600 IQ LX CFI SO8PP6HS SO8PR6HS Ref it Inaui h oak S08PR6HE 600 Switchback eference Unit Inquiry on the dealer website to lookup affected Snowmobile VINs A 600 Dragon Switchback SO8PS6HE g SO8PT6HS SO8PT6HE 600 Touring CFI SO8PB7JS SO8PB7JE 700 IQ SO8PP7JS SO8PP7JE 700 Dragon IQ SO8PR7JS SO8PR7JE 700 Switchback SO8PS7JS
3. ENT HAS BEEN COMPLETED Please contact your authorized Polaris snowmobile dealer immediately to schedule a service visit for inspection and or replacement Your authorized Polaris snowmobile dealer has been issued Safety Bulletin S 09 06 The Safety Bulletin instructs your dealer to inspect the fuel hose routing and replace any worn fuel hoses This work will be performed at no charge to you and will take approximately 30 minutes to complete At that time your dealer will also verify any outstanding Technical Service Bulletins have been completed on your snowmobile This notice was mailed to you according to our most current registration information If you no longer own this vehicle or if some of the contact information Such as your address or name in this notice is incorrect please contact your local Polaris dealer to complete a transfer of ownership lf you need assistance with contacting a Polaris Dealer please visit the Polaris web site at www polarisindustries com or call 1 888 704 5290 We apologize for any inconvenience this has caused you sincerely Krog k Laurie Rengel Manager Service Dealer Development amp Warranty
4. SO8PS7JE 700 Dragon Switchback SO9PT6HS S09PT6HE 600 Touring CFI INSPECTION PROCEDURE Hose properly located in P clamp 1 Open the hood and inspect the return fuel hose where the P clamp secures it to the airbox If the hose is located as shown in PHOTO A no further action is required Close the hood and file a warranty claim for S 09 06 Inspection Only 2 Ifthe return fuel hose is located as shown f in PHOTO B inspect the CONTACT n AREA as shown in PHOTO B Gap between supply and 3 When inspecting the hoses for wear verify f return hoses the wear hasn t penetrated the outer braided wrap and damaged the inner black fuel hose as shown in PHOTO C PHOTO D shows hose wear that is i f acceptable and doesn t require hose 4 PHOTO A replacement EE TN A PHOTO A 4 If no hose wear is found loosen the P i clamp screw and adjust the supply fuel hose so that it is mounted as shown in PHOTO A File a warranty claim for S 09 06 Inspection Only 5 If hose wear is found replace the hose s when the wear has penetrated the braided wrap and damaged the inner black hose Reference the REPAIR PROCEDURE section 6 Ifthe fuel supply hose is replaced file a warranty claim for S 09 06A Inspection Fuel Supply Hose Replacement 7 Ifthe fuel return hose is replaced file a warranty claim for S 09 06B Inspection Fuel Return Hose Replacement 8 If both the fuel supply and fuel return hoses require replace
5. ilter PARTS AVAILABILITY S 09 06B Inspection Return Hose Replacement Only 7170107 QTY 1 Bulletin Completion Decal cae NUS Coen ten 2520648 QTY 1 ASM Fuel Return Hose PARTS AVAILABILITY S 09 06C Inspection Supply and Return Hose Replacement Only 7170107 QTY 1 Bulletin Completion Decal PART NUMBER DESRIPTION 2520647 QTY 1 ASM Fuel Hose w Filter 2520648 QTY 1 ASM Fuel Return Hose PARTS AVAILABILITY YES 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 S 09 06 Inspection Only SERVICE BULLETIN S 09 06 CLAIM TYPE SB Service Bulletin LABOR ALLOWANCE 12 Minutes CLAIM PART NUMBERS N A Auto Process Bulletin S 09 06A Inspection Supply Hose 2520647 Replacement Onl CLAIM TYPE SB Service Bulletin LABOR ALLOWANCE 24 Minutes CLAIM PART NUMBERS N A Auto Process Bulletin S 09 06B Inspection Return Hose 2520648 Replacement Onl CLAIM TYPE SB Service Bulletin LABOR ALLOWANCE 24 Minutes CLAIM PART NUMBERS N A Auto Process Bulletin S 09 06C Inspection Supply and Return Hose 2520647 and 2520648 Replacement Only SERVICE BULLETIN S 09 06C CLAIM TYPE SB Service Bulletin LABOR ALLOWANCE 30 Minutes CLAIM PART NUMBERS N A Auto
6. ment file a warranty w claim for S 09 06C Inspection Fuel Supply and Return Hose Replacement PHOTO B A Inner fuel hose is damaged Braided wrap is not penetrated Hose must be replaced No replacement required REPAIR PROCEDURE s Remove the console from the snowmobile 2 Follow the Fuel Rail Bleeding and Disconnect Fittings sections located on pages 4 35 and 4 36 in the 2007 2009 IQ Service Manual PN 9921985 3 Remove the damaged hose s from the filter connection and fuel tank fittings 4 Reinstall a new fuel supply hose w filter PN 2520647 or return hose PN 2520648 or both if required Verify an audible click is heard when pushing the fuel hose connectors together Firmly pull at the connections to confirm the hose connections are secure Install the P clamp as shown in PHOTO A Reinstall the console Close the hood and file a warranty claim for S 09 06A if only replacing the fuel supply hose File a warranty claim for S 09 06B if you replace the return hose File a warranty claim for S 09 06C if both the supply and return fuel hoses are replaced LO pI PARTS INFORMATION S 09 06 Inspection Onl PART NUMBER DESRIPTION 7170107 QTY 1 Bulletin Completion Decal PARTS AVAILABILITY TO BE ORDERED BY DEALER S 09 06A Inspection Supply Hose Replacement Onl 7170107 QTY 1 Bulletin Completion Decal Paes ees 2520647 QTY 1 ASM Fuel Hose w F
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