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December 7, 2012
Subject: 2013 600/800 PRO-RMK Drive Shaft Collar Kit Installation
Purpose:
The Polaris Technical Service and Snowmobile Engineering teams have received field reports of broken drive shafts on a limited number of MY13 600 and 800 PRO-RMK snowmobiles. This condition has been caused by a manufacturing process variation resulting in insufficient press fit and strength between the drive shaft and sprocket-side hub insert.
While affected parts represent only a small percentage of total production, Polaris will fully stand behind every sled produced and apply the repair to 100% of MY13 PRO-RMK models. Please perform this Service Bulletin on all 2013 600 and 800 PRO-RMK units. This ensures our customers will have full confidence their snowmobiles will not experience a drive shaft separation. The repair is simple and effective, and must be performed by Polaris dealerships on consumer units and wholegood inventory.
The Drive Shaft Collar Kit (PN 2205108) can be installed quickly and without removing the drive shaft. Effective installation requires inspecting the drive shaft, cleaning the drive shaft tube, proper alignment of the collar, and tightening the collar fasteners to specification. Please reference the kit instructions beginning on page 5 of this Service Bulletin.
Completion of this Service Bulletin is being expedited to ensure minimum impact on your customers’ riding season. Service kits will be shipped immediately to your dealership with priority shipments going to dealers in high-altitude regions. Our plan is to ship kits to update no less than 75% of your MY13 PRO-RMK wholesale order by December 24, 2012. We plan to ship the remaining kits no later than January 4, 2013
Please notify your customers of this bulletin and repair. In addition, Polaris will mail a notification letter to all customers who have taken delivery of an affected unit on or before December 7, 2012. Included with the notification letter will be a voucher for a free gallon of VES Synthetic Oil. A copy of the customer notification can be found on page 4.
Again, we take quality very seriously, and want you to be confident we have taken appropriate measures to prevent this from reoccurring. Thank you for everything you do to service Polaris customers and provide the best snowmobiling experience possible.
S-12-05 Service Bulletin Notes:
The kit instructions outline an inspection procedure. If the original drive shaft does not pass the inspection, order and install a new drive shaft.
Do not install the collar on a drive shaft that does not pass inspection, has been drilled and had rivets installed or incurred damage from any other form of aftermarket modification.
If installing a new drive shaft, submit a warranty request with photos through ASK Polaris for approval.
If installing a new drive shaft from current inventory, inspect the drive shaft as outlined in the instructions,
and install the collar kit prior to installing the drive shaft in the snowmobile.
The part number for the MY13 bonded drive shaft has changed to 1590522 indicating the collar is already installed by Polaris. If installing PN 1590522, file a warranty claim as outlined above and a warranty claim for Service Bulletin S-12-05 to close the Service Bulletin.
To facilitate dealers that service additional vehicles, the repair kit will be made available for sale after all direct shipments are completed by Polaris.
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 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 Sales Inc.
© 2012 Polaris Sales Inc. Page 1 of 4
S-12-05 2013
Affected Models:
Model Year
Models
Model Numbers
Vehicle Identification Number Range
2013
600 PRO RMK 155
S13CG6GEA S13CG6GSA S13CG6GSL
Reference Unit Inquiry on the dealer website or the Service Bulletin list on the STOP site to lookup affected snowmobile models.
800 PRO RMK 155
S13CG8GDA S13CG8GEA S13CG8GEB S13CG8GSA S13CG8GSB S13CG8GSC S13CG8GSL S13CG8GSM S13CG8GSP
800 PRO RMK 163
S13CH8GDA S13CH8GEA S13CH8GSA S13CH8GSB S13CH8GSC S13CH8GSL S13CH8GSM S13CH8GSP
Warranty Coverage Period:
Warranty coverage for Service Bulletin S-12-05 begins on December 7, 2012 and will expire on June 30, 2014. All affected vehicles are covered during the campaign period. After the expiration date, only wholegoods stock (WS) and vehicles still within the standard warranty period will receive warranty coverage. Vehicles outside the standard warranty period will not receive warranty coverage after the expiration date.
S-12-05 Parts Information:
SERVICE BULLETIN #
S-12-05
PART NUMBER/QTY./ DESCRIPTION
2205108 (QTY.1) – MY13 PRO-RMK Drive Shaft Collar Kit 7170107 (QTY.1) – Bulletin Completion Decal
PARTS AVAILABILITY
N/A
DIRECT-SHIP FROM POLARIS?
YES – Repair kits will begin shipping immediately. Polaris will debit the cost of the repair kit from your parts account. Repair kit cost will be reimbursed when your dealership files a warranty claim for this Service Bulletin.
TO BE ORDERED BY DEALER?
Dealers will be able to order repair kits after all direct shipments are completed by Polaris.
NOTE: The MY13 PRO-RMK Drive Shaft Collar Kit (PN 2205108) MUST be installed on all MY13 bonded drive shafts with the part number 1590508. This includes drive shafts on vehicles and service parts inventory at, or in transit to, your dealership. At the time of this publication, drive shaft part number 1590508 has been superseded to 1590522. The new drive shaft part number indicates the collar has already been installed by Polaris.
Parts Return or Disposal Information:
Dealers & Distributors: Under no circumstances shall the part removed in this repair be re-used, sold, or re-purposed for another application. It is your dealership / distributorship’s responsibility to make sure every part replaced is taken out of circulation and disposed of properly.
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 Polaris has asked for the part(s) to be returned. If the part(s) were not identified as needing to be returned to Polaris, please dispose of the part(s) properly.
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 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 Sales Inc.
© 2012 Polaris Sales Inc. Page 2 of 4

S-12-05 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.
Bulletin Completion Decal:
A Bulletin Completion Decal, PN 7170107, must be completed for this repair. Attach the decal to the air box assembly. If you require more decals, order them through normal Polaris parts ordering channels.
CUSTOMER NOTIFICATION:
Dealers are required to notify owners of affected models, and make arrangements to perform this repair. To view a list of your dealership’s affected units, utilize Service Bulletin lookup located at:
https://www.polarisdealers.com/servwarr/SrvBulletins.asp
SERVICE BULLETIN #
S-12-05
CLAIM TYPE
SB (Service Bulletin)
LABOR ALLOWANCE
30 Minutes
CLAIM PART NUMBERS
N/A - Auto Process Bulletin
WARRANTY COVERAGE PERIOD
December 7, 2012 – June 30, 2014
In addition, Polaris will be mailing a notification letter to all owners of affected models. on page 4.
Sincerely,
Bridget McLennan
Technical Service, Warranty and Service Publications Manager
A copy of the letter can be found
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 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 Sales Inc.
© 2012 Polaris Sales Inc. Page 3 of 4
December xx, 2012
VIN
FIRST NAME LAST NAME ADDRESS
CITY, ST ZIP
Dear FIRST NAME.
Thank you for purchasing a 2013 Polaris PRO RMK snowmobile. Our number one priority at Polaris is customer satisfaction, and we know this is driven by product quality. Recently we identified a quality concern that affects 2013 PRO RMK snowmobiles, including your machine. Please take a moment to review this letter and make arrangements with your Polaris dealer to have it resolved.
On December 7, 2012, Technical Service Bulletin S-12-05 was released because it is possible your vehicle’s drive shaft may separate due to an incorrect assembly process. To resolve this issue, Polaris has provided your selling dealer with a service procedure and repair kit for your snowmobile to install a drive shaft collar at no cost to you.
While affected parts represent only a small percentage of total production, Polaris is standing by our product and will perform the repair so you can be completely confident you will not experience this condition. It is not possible at this time to clearly differentiate normal and affected vehicles by inspection or VIN, so do have this repair implemented by your selling dealer. The repair is simple and effective, and must be performed by your Polaris dealer to ensure proper installation.
Please note that only the Polaris service part and installation procedure have been validated to adequately correct this condition. Any aftermarket solution should be immediately replaced by your dealer with the correct Polaris part (Drive Shaft Collar Kit (PN 2205108). The drive shaft must be replaced if the aftermarket solution involved drilling the drive shaft and installing rivets or the aftermarket collar damaged the drive shaft. If the drive shaft requires replacement because of aftermarket solution damage, we will replace your drive shaft at no cost to you.
The repair kit is shipping to your dealer now. While the repair procedure will take no more than 30 minutes to perform, dealer service schedules vary so please contact your selling dealer at your earliest convenience to schedule a service appointment.
As a thank you, for your loyalty to Polaris, we have enclosed a coupon good for one free gallon of VES Synthetic Oil. Once the Service Bulletin has been completed, you can use the voucher at your dealership to pick up your free oil.
While your Polaris 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 Department at: 1-888-704-5290.
We take quality very seriously, and want you to be confident we have taken appropriate measures to prevent this from reoccurring. Thank you for being part of the Polaris family and allowing us to provide you with the ultimate deep snow riding experience.
Sincerely,
Polaris Snowmobile Division
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 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 Sales Inc.
© 2012 Polaris Sales Inc. Page 4 of 4

DRIVE SHAFT COLLAR KIT
P/N 2205108 Application
MY 13 Polaris PRO RMK’s, 600 and 800’s, 155” and 163” tracks
Before you begin, read these instructions twice and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information.
This Kit Includes:
Qty Part Description
2....... Bond-Drive Shaft Collar 2....... Bolt
1....... Instructions
Part Number
5138828-W 7519877 9924506
Tools Required:
Gasket Scraper Torque Wrench
6 mm Allen Head Socket (not ball end) Blue Threadlocker
NOTE: Loctite 243 MSDS can be found at:
http://www.henkelna.com/industrial
IMPORTANT: For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence as shown on the attached instructions. Please wear safety glasses while performing the steps in the following instructions.
INSTALLATION INSTRUCTIONS
NOTE: Before you install this kit you should bring your vehicle into a dry warm area. Your vehicle should be at room temperature. It should be dry and clean, free of snow, ice and debris.
1. Place suitable protection on floor and roll vehicle onto its left side. See Figure 1.
Lay Vehicle on Left Side
Figure 1
2. Inspect shaft for separation of end cap, breakage
or other damage. Remove decals, make sure drive shaft is clean, free of dirt, ice and other contaminants. See Figure 2.
NOTE: Replace shaft if gap is observed or if shaft is broken.
Remove Decals Remove Adhesive Remove all Burrs Clean Area
Figure 2
Inspect for any Gaps
-1-
3. Scrape off any excess adhesive protruding from the glue joint using a gasket scraper. Rotate the drive shaft to inspect and remove any adhesive, burrs or surface abnormalities from all six sides. See Figure 3.
4. Apply Loctite® 243 or other blue thread or similar medium strength thread locking product to the end 5/8” of thread on both bolts. See Figure 4.
CAUTION: Ensure Loctite and vehicle is warmer than 50° before installing.
Loctite 243 sets up quickly. The fixture time for Loctite 243 is less than 5 minutes.
Do Not apply Loctite underneath the head of the bolt.
5. Place collar on drive shaft and install bolts. Lightly tighten bolts. See Figure 5.
Scrape Off Excess Glue
Figure 3
Apply Loctite to Bolt
Figure 4
Figure 5
No Overhang
Flush to Seam
6. Slide collar on drive shaft until collar aligns with the edge of the hexagonal portion of the drive shaft. Figure 5.
WARNING: It is critical that the collar is properly aligned as shown in illustrations. No portion of the collar should extend beyond the aluminum shaft. See Figure 5.
Figure 6
-2-
7. Torque bolts in 2 steps.
Step 1: Tighten bolts finger tight, approximately to 5 ft. lbs. (6.7 Nm) and check for an equal gap on both sides of the collar.
Step 2: Torque bolts to 25 ft. lbs. (33.8 Nm) and check for equal gap.
NOTE: It is important that the hex Allen socket keep aligned with the bolt during the torque process or
bolt head damage will occur DO NOT use a ball end socket for torqueing bolts.
CAUTION: Rotate the track to ensure proper installation of collar. Inspect drive shaft for straightness, contaminants and proper alignment as noted in Figure 5.
8. Place vehicle in upright position.
9924506 Rev01 12/12
Printed in the U.S.A.
-3-
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