SUBJECT: SAF-12-02 - Drive Shaft Field Issues
DATE: November 30, 2012 MODELS: 2013 600 / 800 PRO-RMK 155/163 Snowmobiles
*** Important Service Information ***
Please distribute to Service Manager, Parts Manager, and Service Technicians
The Polaris Technical Service and Snowmobile Engineering teams have received field reports of broken drive shafts on a limited number of 2013 600 and 800 PRO-RMK snowmobiles. Please review this service communication carefully to learn what we currently know at the time of this publication, what our engineering and service plan is moving forward, and what Polaris dealers can do to assist Polaris in resolving this issue.
What we know:
 The bonded drive shaft used on MY13 600 and 800 PRO RMK snowmobiles passed rigorous field and lab testing prior to full production, and Polaris is committed to standing behind this product.
 A limited number of Polaris dealers have reported that the sprocket-side hub insert is separating from the tubular drive shaft housing on some consumer snowmobiles.
 As of today, we have received 70 reported failures. Although this represents only a small fraction of the total registered snowmobiles in the field, we will move quickly to resolve this issue for affected customers.
 There have been no failures involving the clutch-side hub insert dislodging from the drive shaft tube.
Current engineering and service plan:
 Our primary focus is to identify the root cause of the hub insert separating from the housing and to determine appropriate corrective action. The snow engineering teams are currently analyzing all drive shafts that have been returned from the field.
 The Polaris service department is logging all field cases from dealers. When we receive a call or ASK Polaris Case, we request detailed information, including photos of the drive shaft, and ask that the shaft be returned to Polaris according to the normal parts return process after the claim has been filed.
 The Polaris parts department has placed all bonded drive shafts on backorder status. This action was taken to ensure drive shaft availability for snowmobiles currently down for repair. At this time, replacement shafts will be shipped only to dealers with confirmed ASK Polaris cases on file.
 When root cause and resolution have been finalized, an official repair notification will be published for the affected vehicles. As stated above, Polaris will stand behind this product and support our customers.
What dealers can do to assist Polaris:
 If your dealership encounters a snowmobile with a broken drive shaft, please submit an ASK Polaris case with failure details and photos immediately. Monitor your warranty parts return list and return the drive shaft to the Polaris warranty department using the pre-paid UPS shipping label as soon as possible.
 Please submit the ASK Polaris case quickly and immediately order the part. We will manage all cases and parts orders individually. In order to minimize vehicle downtime we MUST have a case and a parts order.
 Refrain from promoting non-Polaris remedies that modify or alter the original drive shaft design. We are focusing all efforts on identification and testing and cannot speculate on the performance of these non-Polaris remedies.
o Do not attempt to drill or tap into the stock shaft; doing so will compromise bonding material integrity.
o While steel drive shafts from other RMK models may fit, Polaris does not recommend this because there is a risk of the shaft seizing on to the inner bearing race and lower drive sprocket.
