Page 1 PROSPECTOR 2014 ATV TRACK KIT 9925023 - VERSION A USER MANUAL...
Page 3: Table Des Matières
TABLE OF CONTENTS SAFETY ............1 TENSIONER WARNING .
Page 4: Safety
SAFETY SAFETY This guide uses the following symbols to emphasize particular information: WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in damage to vehicle components. NOTE: Indicates supplementary information.
Page 5 They contain important information about safety and proper operation of the track systems. Do not remove the warning stickers from the frame. If a sticker is damaged, have it replaced by an authorized Polaris dealer.
Page 6: Tensioner Warning
SAFETY USER MANUAL - Every user must read the User Manual before attempting to operate a vehicle equipped with track systems. If track systems are sold or in any way tranferred to a new user, the User Manual must also be transferred to the new user.
Page 7: General Information
GENERAL INFORMATION GENERAL INFORMATION All figures, information or photos presented in this document are up to date at the time of publication. However, they may change without notice. Read and follow indications of the ATV user manual and installation guidelines carefully. Their contents remains applicable after installating of the System.
Page 8 USING THE ATV WITH TRACKS USING THE ATV WITH TRACKS When using a vehicle equipped with track systems, it is important to respect the following safety recommendations. As driving a vehicle equipped with track systems is different from driving a vehicle with wheels, it is strongly recommended that the safety guidelines provided below are followed to prevent any accidents and serous malfunctions that could affect the occupants, the vehicle or to the track systems for occurring.
Page 9: Using The Atv With Tracks
USING THE ATV WITH TRACKS Steep descents WARNING It is not advisable to change direction during steep descents. This can lead to a serious malfunction of the ATV’s steering system and track systems. During a steep descent, it is advisable to keep the handlebars in a forward direction and begin turning when the ATV is on flat ground, thus avoiding subjecting the vehicle components and the system to any high stress.
Page 10 USING THE ATV WITH TRACKS Descending and being stuck in reverse WARNING If the rear track systems get stuck in the snow, avoid moving or towing the vehicle in reverse to ease it from its position, as this could lead to a malfunction of the systems. If possible, move it in the forward direction to free it from the snow.
Page 11 USING THE ATV WITH TRACKS Towing a vehicle out of the snow WARNING If your vehicle must be towed out of the snow, never tow it in the direction in which it sank. Tow the vehicle in the direction of the trail it left as it became stuck.
Page 12 USING THE ATV WITH TRACKS Driving over an obstacle Driving over a steep ridge WARNING It is not advisable to attempt to drive over an obstacle, such a tree trunk, a big rock or a steep ridge that could lodge itself between the front and the rear track systems and immobilize the vehicle.
Page 13 USING THE ATV WITH TRACKS Driving over an obstacle of more than 12 inches WARNING It is not advisable to attempt to drive over an obstacle of more than 12 inches, such a tree trunk, a stump or a large rock.
Page 14 USING THE ATV WITH TRACKS Loading a vehicle into and unloading it from a truck WARNING When a vehicle is being loaded into or unloaded from a truck box, it is extremely important to ensure that the front tracks do not grip the locking gudgeons of the truck’s tailgate as this could cause them to tear.
Page 15 USING THE ATV WITH TRACKS Jumping WARNING It is strictly forbidden to jump with vehicles equipped with track systems. These systems were not designed to carry out this type of operation. An ATV equipped with the system must never be used for the following activities: races, rallies, jumps, stunts, acrobatics or any other extreme applications.
Page 16 USING THE ATV WITH TRACKS WARNING The driving characteristics of your ATV will change with the installation of the System. It is important to take the time to become familliar with the Systems. WARNING It is the driver’s responsibility to verify that the air intake of the vehicle is well adapted to weather conditions and is not blocked by snow accumulation.
Page 17: Installation, Removal And Re-Installation
INSTALLATION, REMOVAL AND RE-INSTALLATION INSTALLATION, REMOVAL AND RE-INSTALLATION WARNING Never place body parts under the vehicle unless it is securely placed on appropriate stands. Severe injuries could occur if the vehicle collapses or moves. Do not use a lifting device as a secure stand. Always follow good shop practices.
Page 18 INSTALLATION, REMOVAL AND RE-INSTALLATION WARNING To avoid any injury to your hands during manipulation of the systems, we recommend handling the systems with hands placed on the frame at the positions shown in the figure below. Installation Execute all tasks described in Installation Guidelines of the vehicle model.
Page 19 INSTALLATION, REMOVAL AND RE-INSTALLATION • Remove the anti-rotation bracket cover (1) but keep the anchor bracket (2) attached to the anti-rotation device on the track system. NOTE: Leave anchor bracket (2) attached to stabilizing rod (3). Figure 1 • Remove track systems. •...
Page 20 INSTALLATION, REMOVAL AND RE-INSTALLATION Re-installation Always clean wheel hubs on the ATV before installing wheels or track systems. Figure 2 NOTE: Clean wheel hubs. • Re-install track systems at the rear. • Re-install track systems at the front. • Tighten fasteners in criss-cross pattern to the manufacturer’s recommended torque specification.
Page 21: Adjustments
ADJUSTMENTS ADJUSTMENTS IMPORTANT Verifying your adjustments on the system is mandatory after the first use of the vehicle, the track tension, alignment and angle of attack of the each track system must be re-verified. Incorrect adjustments can decrease the performance of the system and create premature wear of certains components NOTE: To make the following adjustements, position the vehicle on a flat and level surface...
Page 22 ADJUSTMENTS • Verify that spring assembly bolt (1) is tightened to the recommended torque [40 N•m] and that stabilizing arm components are installed in the correct order. See Figure 4. Figure 4 • Position a flat bar across both rear wheels of front track system and measure from the ground up to flat bar as shown on Figure 5.
Page 23 ADJUSTMENTS • Loosen jam nut (1). Adjust length of rod end (2) by rotating the stabilizing arm (3) to obtain 270 mm [10 5/8 in] above the ground. Refer to Figure 6. NOTE: Before each measurement, temporarily apply light pressure to the front of the track to make sure that it stays flat on the ground.
Page 24 ADJUSTMENTS Basic Tuning (front track systems): • An adjustment of more than 270 mm [10 5/8 in], measured with the flat bar, provides easier steering and produces a wobbling effect at high speed. • An adjustment of less than 270 mm [10 5/8 in], measured with the flat bar, results in harder steering and more stability at high speed.
Page 25 ADJUSTMENTS Angle of attack for rear track systems To obtain the correct angle of attack on rear tracks systems, perform the following: • Stabilizing arm (1) must be attached to the rear anchor bracket (2) installed on the vehicle. See Figure 8. Figure 8 •...
Page 26 ADJUSTMENTS • Loosen anti-rotation bracket bolts (1) and (2) to allow the anti-rotation retainer (3) to rotate on its axis. See Figure 10. Figure 10 • Loosen jam nut (1). Rotate the stabilizing arm to adjust length of rod end so that no pressure is applied to the rubber cone (2).
Page 27 ADJUSTMENTS • Position the anti-rotation retainer at 90 (perpendicular) with the stabilizing rod. Tighten the two anti-rotation bracket mounting bolts (1 and 2) to 50 N•m of torque. Refer to Figure 12. Figure 12 • Turn stabilizing arm nut to adjust length of rod end (1) so that rubber cone (2) applies light pressure on anti–rotation retainer (3).
Page 28 ADJUSTMENTS • Re-tighten jam nut (1) when adjustment is complete. See Figure 14. Figure 14 NOTE: Once adjustment of the angle of attack on rear systems is complete, verify once again to confirm the adjustment setting. Basic tuning (rear track systems): •...
Page 29 ADJUSTMENTS Alignment Parallelism must be adjusted with the ATV on the ground, driving forward on about 3 m [10 ft] and measuring toe-in distance. Refer to Figure 15. NOTE: Every time the measurement has to be verified, drive in reverse, then, drive forward again on about 3 m [10 ft].
Page 30 ADJUSTMENTS To perform adjustments on the ATV, first unlock the nut (1) of each tie rod end on the ATV. Then screw or unscrew the rod link (2) equally on both sides of the vehicle. Figure 16...
Page 31 ADJUSTMENTS Rubber track tension To adjust the track tension, loosen the track tensionner nylon nut (1) and loosen jam nut to unlock adjustment nut (2). Turn the 14 mm adjustment nut (2) clockwise or counter-clockwise to adjust the track tension to the recommended specification. Figure 17 When the track tension adjustment is done, lock adjustment nut with jam nut and tighten the track tensionner assembly nut (1)
Page 32 ADJUSTMENTS The following table indicates the force (1) applied and the deflection (2) which must occur according to the conditions of use. Season Track Force Deflection Front 15 kg 19 mm Summer Rear 15 kg 19 mm Front 11 kg 19 mm Winter (snow) Rear...
Page 33 ADJUSTMENTS Basic tuning • A higher rubber track tension reduces the risk of “derailing” and reduces drive “ratcheting”. • A lower rubber track tension provides better performance, better rolling and better fuel economy. Final check Ride at slow speed for approximately 1.5 km. Evaluate track system performance and re-adjust as required.
Page 34: Installation Of A Rubber Track
INSTALLATION OF A RUBBER TRACK INSTALLATION OF A RUBBER TRACK If possible, position the vehicle on a flat and level surface (or on a suitable lift device). Turn off the engine. Proceed as follows: • Loosen track tensionner assembly nut (1). •...
Page 35 INSTALLATION OF A RUBBER TRACK • Remove the two 202 mm wheels from the track tensioner. Refer to Figure 21. Figure 21 • Install the rubber track. Refer to Figure 22. NOTE: Look for the mark on the track indicating the correct orientation.
Page 36: Break-In Period
BREAK-IN PERIOD BREAK-IN PERIOD A break-in period is necessary in order to allow the components of the system to settle themselves in relation to each other. During the break-in period (4 hours or 80 kilometers), follow these recommendations: • Avoid riding under dry and clean conditions. (For example: asphalt, hay or straw field, etc).
Page 37: Maintenance Schedule
MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE WARNING Do not insert hands or feet into or near the System unless the engine is off, and the vehicle is stopped with the security brake engaged. . WARNING Regular inspection, adjustment and lubrication of the track systems is essential to their good running order and safe operation.
Page 38 MAINTENANCE SCHEDULE...
Page 39: Maintenance - Tasks
MAINTENANCE SCHEDULE Maintenance - Tasks • Inspect: Component(s) must be examined with care. If an anomaly is noticed, the malfunctioning component(s) must be repaired or replaced. • Clean: Component(s) must be cleaned of any dirt, dust or contaminant liable to impair the proper operation of the track system.
Page 40 MAINTENANCE SCHEDULE Track • Tension: Perform or check track tension on the systems according to the manufacturer’s recommendations. Refer to the “Rubber track tension” section of the User Manual on page 28. • Wear: Check wear and overall condition of the tracks on the systems.
Page 41 MAINTENANCE SCHEDULE • Track guide wear: Check wear on track guides. Refer to the “Wear” section of the User Manual on page 52. Replace guides if wear is too great. • Stabilizers: Verify condition of rubber cones on the stabilizer assembly of front systems and wheel axle assembly of rear systems.
Page 42 MAINTENANCE SCHEDULE WARNING After use in an extreme environment (mud and water) and at annual inspection of all bearings, please remember that the bearings cannot be re-greased like snowmobile bearings. If they need to be serviced, replace the wheel completely. Some of the components (i.e.
Page 43: Lubrication
LUBRICATION LUBRICATION...
Page 44 LUBRICATION LUBRICATION The Maintenance Schedule chart on page 35 includes lubrication maintenance that should be performed on track systems. Refer to the following recommendations for optimal lubrication. NOTE: Use a water-resistant anti-friction synthetic grease. Aerochem MF grease is recommended. REFERENCE “A” LUBRICATION OF 134 mm AND 202 mm WHEELS Apply evenly 1 to 1.5 cc (cubic centimeter) of grease over the entire circumference (360°) of the inner steel washer.
Page 45 LUBRICATION REFERENCE “B” LUBRICATION OF HUB BEARING SEALS Apply evenly 1.5 to 2 cc (cubic centimeter) of grease between the hub seal’s lips and over its the entire circumference (360°) IMPORTANT : The hub seal must not extend beyond the hub face.
Page 46 LUBRICATION REFERENCE “C” LUBRICATION OF THE HUB SPEED SLEEVE Apply 1 to 1.5 cc (cubic centimeter) of grease over the entire width and circumference (360°) of the hub speed sleeve.
Page 47 LUBRICATION REFERENCE “D” HUB LUBRICATION Remove small bolt on top of the system’s frame and pour 10 to 12 cc of 80w90 grade oil on hub shaft through tapped hole. WARNING Be careful not to use too much oil. An excessive amount of oil could damage the seal and cause oil leakage.
Page 48 LUBRICATION REFERENCE “E” STABILIZER SHAFT LUBRICATION Apply evenly 1 to 1.5 cc (cubic centimeter) of grease all around (360°) the stabilizer shaft and over its entire length.
Page 49 LUBRICATION REFERENCE “F” STABILIZER BORE LUBRICATION Apply evenly 1 to 1.5 cc (cubic centimeter) of grease inside the stabilizer shaft bore, over its entire length and circumference (360°).
Page 50 LUBRICATION REFERENCE “G” STABILIZER BOLT HEAD LUBRICATION Apply evenly 0.75 to 1.5 cc (cubic centimeter) of grease on the stabillizer mounting bolt head. Apply over the entire circumference (360°).
Page 51 LUBRICATION REFERENCE “H” LUBRICATION OF STABILIZING ARMS Apply spray lubricant (e.g. motorcycle chain grease) all around the stabilizing arm compression spring and over its entire length. FRONT SYSTEMS REAR SYSTEMS...
Page 52: Torque Specifications
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Refer to the exploded views at the end of the Manual to obtain torque specifications applied to bolts at important points on the track system. NOTE: Use a threadlocker (Loctite 263 type or its equivalent) at the indicated places in the exploded views of the system.
Page 53: Wear
WEAR WEAR Wheel Verify wheel wear especially on the interior guiding strip (see Figure 24). If the internal plastic structure is visible, the rubber coating is worn and the wheel must be replaced (see Figure 25), or when the width of the wheel’s rolling band reaches 17 mm, (see Figure 26: 20.5 mm when new).
Page 54 WEAR Figure 25 Figure 26...
Page 55 WEAR Track guide Verify the wear of the track guide by measuring the width of the guide. If dimensions of the guide illustrated in Figure 27 are less than 5 mm, at any place, replace the part. If the guiding strips are so worn that the concave shape is no longer visible, replace the part.
Page 56 WEAR Sprocket Check sprocket wear by measuring the part as illustrated on Figure 28. Replace the part when dimensions are less than 19 mm. Excessive wear could lower track drive efficiency and reduce the system’s performance. Figure 28...
Page 57 WEAR Anti-rotation Verify the wear of anti-rotation system, mainly at the ball joint (Figure 29) to make sure that it is not seized or extremely loose. Ball joint damage could harm the performance of the track system. Figure 29 Check if ball rotates freely in ball housing and check also that there is not excessive play between ball and ball housing (Figure 30).
Page 58: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING Problem Potential cause Correction Remove any debris which could prevent the Presence of debris in the system. proper operation of the system Severe and localized wear of a wheel (flat spot) Replace the part Remove the ice/snow build-up. Storing the vehicle at temperatures higher than 0 °C might be Frozen sprocket or wheel required.
Page 59: Serial Number Location
SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION The following pictures show the location of the serial numbers on the track system frame (Figure 31) and rubber track(Figure 32). Figure 31 Figure 32...
Page 60: ''Ce'' Declaration Of Conformity
Shawinigan (Québec), Canada G9N 6T6 PHONE : FAX : WEB SITE : www.camoplastsolideal.com HEREBY DECLARE THAT THE PRODUCT SERIES PRODUCT : Polaris Prospector Pro ATV CUSTOMER : IS IN CONFORMITY WITH THE FOLLOWING STANDARDS NUMBER : TITLE: DATE: -EN 62079...
Page 61 EXPLODED VIEWS POLARIS PROSPECTOR PRO ATV...
Page 62 PART # DESCRIPTION 2205425 KIT- FRAME, CMPLST, CAST, ATV UPPER CARRIER / SUPPORT SUPÉRIEUR HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS HSBS, M6-1X10, 10.9, ZP W, 9.9X6X0.9, AL STICKER WARNING / AUTOCOLLANT AVERTISSEMENT STICKER / AUTOCOLLANT -- POLARIS ATV STICKER / AUTOCOLLANT -- PROSPECTOR PRO ATV ERR, 35, 2.4, ZP, SHR-137...
Page 63 ITEM # PART # DESCRIPTION 2205427 KIT - FRAME, CMPLST, PLASTIC, RR, ATV REAR PLASTIC BASE ASSEMBLY WITH SHAFTS / BASE PLASTIQUE ARR.+ ARBRES TRACK GUIDE / GUIDE CHENILLE 2205428 RWHS, 6X16, TX, ZP ITEM # PART # DESCRIPTION 2205433 K-SPROCKET, CMPLST, 18 TOOTH SPROCKET-CMPLST XP, 18 TOOTH HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921...
Page 64 ITEM # PART # DESCRIPTION 2205432 K-SPROCKET, CMPLST, 20 TOOTH SPROCKET-CMPLST XP, 20 TOOTH HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 ITEM # PART # DESCRIPTION 2205434 K-HUB, CMPLST, 13mm HUB-CMPLST XP 13mm, ASSY HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 ERR, 35, 2.4, ZP, SHR-137...
Page 65 ITEM # PART # DESCRIPTION 2205435 K-HUB, CMPLST, 32mm HUB-CMPLST XP 32mm, ASSY HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 ERR, 35, 2.4, ZP, SHR-137 ITEM # PART # DESCRIPTION 220512 K-WHEEL, CMPLST, ID, ATV WHEEL / ROUE -- ATV 134 MM 2 LIPS CAP, 2"...
Page 66 ITEM # PART # DESCRIPTION 220512 K-WHEEL, CMPLST, ID , ATV 202 MM ATV WHEEL / ROUE ATV 202 MM 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 WHEEL SEAL / JOINT D'ÉTANCHÉITÉ...
Page 67 ITEM # PART # DESCRIPTION 2205430 K-ROCKER, CMPLST, INNER, ATV ATV STABILIZER FEMALE ASS'Y / STABILISATEUR VTT ASSEMBLÉ, FEMELLE DUST CAP, STABILIZER / CAPUCHON, STABILISATEUR HCS, M10-1.5X45, 10.9, ZP, TL, DIN931 W, 7/16X1.0X0.072, 8, ZP, USS ITEM # PART # DESCRIPTION 2205123 KIT - BEARINGS, CMPLST, ATV...
Page 68 ITEM # PART # DESCRIPTION 2205429 K-TRACK ADJUSTER, CMPLST, ATV EXTRUDED TRACK TENSIONNER / TENSIONNEUR DE CHENILLE CB, M10-1.5X70, 8.8, ZP, DIN603 TENSIONER BUSHING / COUSSINET TENSIONNEUR W, 20X10.5X2, ZP, DIN125A FNN, M10-1.5,8,ZP, DIN6926 TENSIONNER ROD - HEX NUT ASS'Y / ENS. TIGE TENSIONNEUR - ÉCROU HEX STICKER - LOOSEN / AUTOCOLLANT - DESSERRER ITEM # PART #...
Page 69 ITEM # PART # DESCRIPTION 2205438 KIT- ANTI ROTATION, CMPLST, ATV SHORT ANTI-ROTATION TUBING WELDMENT / TUBE ANTI-ROTATION COURT, SOUDÉ HCS, M10-1.5X60, 10.9, ZP, DIN931 HFSCS, M12-1.75X50, 8.8, ZP, FULL THREAD X-LONG ROD END / TIGE À ŒIL X-LONG BUSHING SPACER / BAGUE ESPACEUR -- 3/8'' W, 37X13X3, ZP, DIN 9021 W, 7/16X1.0X0.072, 8, ZP, USS FNN, M10-1.5, 8, ZP, DIN6926...
Page 70 ITEM # PART # DESCRIPTION 2205125 K-HDWR, CMPLST, ATV SPROCKET SPRAPER / GRATTOIR, BARBOTIN HSBS, M6-1X10, 10.9, ZP HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 CB, M10-1.5X70, 8.8, ZP, DIN603 HSFS, M10-1.5X 80, 10.9, ZP SPACER WASHER / RONDELLE ESPACEUR TENSIONER BUSHING / COUSSINET TENSIONNEUR -- XT4S ALIGNMENT SHIM CASTING / CALE D'ALIGNEMENT, SUPPORT SUPÉRIEUR...
Page 71 PART # DESCRIPTION 2205452 K-DECALS, CMPLST, ATV HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS ASSEMBLÉ STICKER - LOOSEN / AUTOCOLLANT - DESSERRER STICKER - WARNING / AUTOCOLLANT - AVERTISSEMENT STICKER / AUTOCOLLANT -- POLARIS ATV STICKER / AUTOCOLLANT -- PROSPECTOR PRO ATV...
Page 72 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO -- LDPE 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO -- ESPRENE DUST CAP, STABILIZER / CAPUCHON, STABILISATEUR HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS ASSEMBLÉ ITEM # PART #...
Page 73 ITEM # PART # DESCRIPTION 5414841 TRACK-CMPLST, REAR, ATV ITEM # PART # DESCRIPTION 2205461 RUBBER CONE, STABILIZER / CÔNE CAOUTCHOUC, STABILISATEUR 2205454 ERR, 35, 2.4, ZP, SHR-137...

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Table des Matières