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Table of Contents
Related Manuals for Polaris PROSPECTOR PRO
Summary of Contents for Polaris PROSPECTOR PRO
- Page 1 UTV TRACK SYSTEM PROSPECTOR PRO 2016 USER MANUAL 9925638...
- Page 2 Industries Inc. LOCTITE® is a registered trademark of Henkel Corporation. Copyright 2015 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
- Page 3 TABLE OF CONTENTS Introduction ......4 Safety ....... . . 6 Operation .
- Page 4 INTRODUCTION INTRODUCTION The following signal words and symbols appear in this manual and on safety labels. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
- Page 5 • Always read this user manual and the PROSPECTOR PRO Track Kit installation instructions for your model before attempting to assemble, install or operate the track system.
- Page 6 Understand all safety warnings, precautions and operating procedures before operating a POLARIS vehicle equipped with a PROSPECTOR PRO track system. Keep this manual with the vehicle. If track systems are sold or transferred to a new user, the user manual must also be transferred to the new user.
- Page 7 OPERATION OPERATION WARNING Failure to operate a track-equipped vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Every user must read and understand this user manual. Always check with local authorities in your intended area of operation to understand laws and restrictions pertaining to the operation of this track- equipped vehicle.
- Page 8 OPERATION Safe Operation Practices 1. Read and understand this user manual and all warning and instruction labels before operating a track-equipped vehicle. 2. Read the vehicle owner’s manual before operating with tracks. Follow all safety and operation warnings and procedures. 3.
- Page 9 OPERATION Safe Operation Practices 9. Always travel at a speed appropriate for your skills and operating conditions. Avoid unexpected or aggressive maneuvers. 10. Operate the vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.
- Page 10 OPERATION Steep Descents POLARIS does not recommend operation of this vehicle on steep hills. Refer to your vehicle owner’s manual for proper operating procedures when driving on inclines. WARNING! Turning a track-equipped vehicle while making a steep descent creates higher stress on steering and track systems, which can lead to component damage and result in an accident or rollover.
- Page 11 OPERATION Freeing a Vehicle Stuck While Backing Downhill POLARIS does not recommend backing downhill with this vehicle. Refer to your vehicle owner’s manual for proper operating pro- cedures when driving on inclines. If backing downhill is unavoidable, back slowly and back straight downhill.
- Page 12 OPERATION Driving Over Obstacles Obstacles are not always visible, especially in areas with deep snow or mud. Avoid operating in areas that are likely to contain hidden obstacles. Refer to your vehicle owner’s manual for proper operating procedures when driving over obstacles. Do not attempt to operate over large obstacles, such as large rocks, tree trunks, stumps or steep ridges.
- Page 13 OPERATION Exceeding Anti-rotation Stroke/Rough Terrain Never exceed anti-rotation stroke of the front and rear track systems. Track system or vehicle failure may occur. Always drive on a surface that fully supports the track systems. Sharp Turns in Locked Differential 4X4 Mode Never make sharp turns in locked diffential 4X4 mode on a sticky terrain without lubrication.
- Page 14 OPERATION Track Damage While Loading/Unloading A track may tear while loading or unloading the vehicle into a truck box if it snags or catches the tailgate latch post. Carefully observe track clearance on both sides of the vehicle while loading or unloading the vehicle.
- Page 15 CAUTION! Hot exhaust system parts can cause burns. Allow components to cool sufficiently before proceeding. Initial Installation POLARIS recommends having your authorized POLARIS dealer perform the initial installation of a track system. 1. Install the track system using the instructions provided with the installation kit.
- Page 16 INSTALLATION/REMOVAL Track System Installation Reinstallation 1. Using a suitable lifting device, elevate the vehicle and place appropriate stands under the frame. Make sure the vehicle is stable. 2. Remove the wheels. 3. Clean the wheel hubs. Components may not seatproperly on soiled hubs. 4.
- Page 17 INSTALLATION/REMOVAL Track System Removal 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the vehicle and place suitable stands under the frame. Make sure the vehicle is immobilized. 4. Remove the anti-rotation bracket cover (1). Remove the anchor bracket (2) from the suspension arm, but leave it attached to the anti-...
- Page 18 ADJUSTMENTS ADJUSTMENTS WARNING! Incorrect adjustments can decrease the performance of the system and create premature wear of components. After the initial installation, and after every future reinstallation of the tracks, always adjust track angle of attack, system alignment and track tension after the first use of the vehicle. Front Track Angle of Attack To obtain the correct angle of attack on front tracks systems, use the following procedure.
- Page 19 ADJUSTMENTS Front Track Angle of Attack NOTE: While performing the measurements in the following steps, apply light downward pressure to the front of the track to ensure it stays flat on the ground. 7. Position a flat bar across both rear wheels of the front track system. Apply light downward pressure to the front of the track while measuring the distance from the bar to the ground.
- Page 20 ADJUSTMENTS Rear Track Angle of Attack To obtain the correct angle of attack on rear track systems, use the following procedure. Refer to the track kit installation instructions for more information as needed. Perform steps 1-3 for both rear track systems.
- Page 21 ADJUSTMENTS Rear Track Angle of Attack 5. Loosen the jam nut (1). Rotate the stabilizing arm to adjust the length of the rod end so that no pressure is applied to the rubber cone (2). 6. Position the anti-rotation retainer at a 90-degree angle to (perpendicular to) the stabilizing rod.
- Page 22 ADJUSTMENTS Front Track System Alignment Inspect steering system components for damage before performing the following front track system alignment procedures. Damaged steering components can adversely affect vehicle operation and prevent proper adjustments to track system alignment. Alignment Inspection 1. Operate the vehicle in a straightahead direction for approximately 10 ft.
- Page 23 ADJUSTMENTS Front Track System Alignment Alignment Inspection A - B = 0 to 1/8 inch (0 to 3 mm) 4. Subtract measurement B from measurement A. The result must be 0 to 1/8 inch (0-3 mm). If the result is not within this range, adjust alignment.
- Page 24 ADJUSTMENTS Track System Alignment Alignment Adjustment 1. Release the coupling lock nuts (1). NOTE: Some nuts have reverse threads. Be sure to unlock the nuts in the proper direction. 2. Screw or unscrew the coupling rods (2) equally on both sides of the vehicle. 3.
- Page 25 ADJUSTMENTS Rubber Track Tension Use the following procedure to make track tension adjustments. CAUTION! DO NOT loosen the tensioner assembly bolt when adjusting track tension. This bolt is used to assemble and align the tensioner with the frame. If this bolt is loosened, tensioner realignment MUST be performed.
- Page 26 RUBBER TRACK INSTALLATION RUBBER TRACK INSTALLATION 1. Position the vehicle on a level surface. 2. Stop the engine. 3. If desired, elevate the vehicle and place appropriate stands under the frame. CAUTION! DO NOT loosen the tensioner assembly bolt under any circumstance. This bolt is used to assemble and align the tensioner with the frame.
- Page 27 RUBBER TRACK INSTALLATION TRACK SYSTEM BREAK-IN Break-In Period The break-in period for a new track system is four hours, or 50 miles (80 km). A proper break-in will result in more efficient performance and a longer life for components. Follow these recommendations during the break-in period: •...
- Page 28 MAINTENANCE MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your system in safe and reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. Perform all inspection and service procedures at the intervals outlined in the Periodic Maintenance Chart. Procedures are outlined in further detail in the following pages.
- Page 29 MAINTENANCE Periodic Maintenance Chart Normal Winter Conditions INITIAL INTERVALS Every Every Annually First Use Hours Hours Page TRACK SYSTEM Visual Inspection Clean; Inspect Clean; Inspect Clean; Inspect Adjustments Adjust Inspect; Adjust Inspect; Adjust System Alignment Adjust Inspect; Adjust Inspect; Adjust Bolt Torque Inspect;...
- Page 30 MAINTENANCE Periodic Maintenance Chart Industrial/Commercial Use/Abrasive Conditions INITIAL INTERVALS Every Every Every First Use Page Hours Hours Hours TRACK SYSTEM Visual Inspection Clean; Inspect Clean; Inspect Clean; Inspect Adjustments Adjust Inspect; Adjust Inspect; Adjust System Alignment Adjust Inspect; Adjust Inspect; Adjust Bolt Torque Inspect;...
- Page 31 MAINTENANCE Perform all inspection and service procedures at the intervals outlined in the Periodic Maintenance Chart beginning on page 28. Track System Maintenance 1. Visually inspect all components of each track system for wear or damage. Clean away any mud, dirt, dust, debris or other substances that could impair the proper operation of the track system.
- Page 32 MAINTENANCE Frame Maintenance 1. Inspect hub bearings for restriction, noise or abnormal play in rotation. Promptly replace all hub bearings if a bearing displays one of these defects. Always replace all bearings any time one bearing requires replacement. 2. Clean and lubricate the hub seal to maintain sealing performance and prolong hub bearing lifespan.
- Page 33 MAINTENANCE Vehicle Maintenance 1. Check the torque of suspension arm bolts. Tighten to specification. Refer to your vehicle owner’s manual or service manual. 2. Inspect and adjust the steering column. Refer to the owner’s manual or service manual for your vehicle. Special tool usage Some components require special tools for servicing.
- Page 34 MAINTENANCE Lubrication Lubricate track system components at the intervals outlined in the Periodic Maintenance Chart beginning on page 28. We recommend the use of a high quality water-resistant anti-friction grease. 132 mm Wheel Bearing Seal - Apply 1- 1.5 cc of grease evenly on and between the wheel bearing seal lips.Apply over the entire circumference.
- Page 35 MAINTENANCE Lubrication Wheel Shaft and Seal Bearing - Apply 1-1.5 cc of grease on the wheel shaft and seal bearing. Apply grease evenly over the entire width and circumference. Hub - After replacing hub housing bearings and reinstalling hub, slowly pour 2 teaspoons (8-10 cc) of 80W90 grade oil through the hole on the top of the hub housing.
- Page 36 MAINTENANCE Lubrication H. Stabilizer Shaft - Using a grease gun, apply 1.5-2 cc of grease to the stabilizer shaft through the grease fitting. Do not overfill. The protective plastic cap could be forced off. I. Stabilizing Arms - Apply spray lubricant around the compression spring and over its entirelength on both front and rear track...
- Page 37 MAINTENANCE Wear Inspections Wheel Wear Inner Surface Excessively worn wheels will not offer enough support for track guidance. Inspect for wheel wear, especially on the interior guiding strips. Replace a wheel if the inner surface is perforated or if the width of the rolling band has worn down to less than 1.75 inches (45 mm).
- Page 38 MAINTENANCE Wear Inspections Track Guide Wear Operating with excessively worn track guides could result in premature wear to other track guidance components. Measure track guide width at multiple positions. Replace the guide if: • any measurement is less than 5 mm or •...
- Page 39 MAINTENANCE Wear Inspections Anti-Rotation Wear Ball joint damage could adversely affect track system performance. Inspect the anti-rotation system for wear, especially at the ball joint. • Make sure the ball joint is neither seized nor extremely loose. • Make sure the ball rotates freely in the housing (1).
- Page 40 TROUBLESHOOTING TROUBLESHOOTING Problem Potential Cause Correction Debris in system Clean/remove all debris. Severe, localized wheel Replace the part. wear (flat spot) Frozen sprocket or Remove ice/snow build-up. Store vehicle at wheel temperatures above 32° F. (0° C). Verify system alignment. Ensure track is Beginning of derailing properly guided by wheels and track guide.
- Page 41 ADDRESS: 4162, rue Burrill, Local A Shawinigan QC, Canada G9N 0C3 PHONE: FAX: WEB SITE: www.camso.co HEREBY DECLARE THAT THE PRODUCT SERIES: PRODUCT: Polaris Prospector Pro UTV CUSTOMER: IS IN CONFORMITY WITH THE FOLLOWING STANDARDS: NUMBER : TITLE: DATE: EN 62079...
- Page 42 2 LIPS CAP, 1-3/4" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 1-3/4 PO 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO CAP NUT / CAPUCHON DE BOULON HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS HSBS, M6-1X10, 10.9, ZP HFCS, M8-1.25X70, 10.9, ZP, IFI536 CP, 1/8, 1-3/4, ZP SDSQWS, #12-24X1.5, ZP...
- Page 43 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO STEEL CAP NUT / CAPUCHON DE BOULON HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS HSBS, M6-1X10, 10.9, ZP HFCS, M8-1.25X70, 10.9, ZP, IFI536 CP, 1/8, 1-3/4, ZP SDSQWS, #12-24X1.5, ZP...
- Page 44 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO STEEL CAP NUT / CAPUCHON DE BOULON HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS HSBS, M6-1X10, 10.9, ZP HFCS, M8-1.25X70, 10.9, ZP, IFI536 CP, 1/8, 1-3/4, ZP SDSQWS, #12-24X1.5, ZP...
- Page 45 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO STEEL CAP NUT / CAPUCHON DE BOULON HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS HSBS, M6-1X10, 10.9, ZP HFCS, M8-1.25X70, 10.9, ZP, IFI536 CP, 1/8, 1-3/4, ZP SDSQWS, #12-24X1.5, ZP...
- Page 46 SERVICE KITS Exploded Views 18-Tooth Sprocket Kit / Ensemble barbotin 18 dents ITEM # PART # DESCRIPTION 2205433 K-SPROCKET, CMPLST, 18 TOOTH SPROCKET-CMPLST XP, 18 TOOTH / BARBOTIN-CMPLST XP 18 DENTS HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 20-Tooth Sprocket Kit / Ensemble barbotin 20 dents ITEM # PART # DESCRIPTION...
- Page 47 SERVICE KITS Exploded Views 32mm Hub Kit / Ensemble moyeu 32 mm ITEM # PART # DESCRIPTION 2205870 K-HUB, CMPLST, 32mm HUB-CMPLST XP HD 32mm, ASSY HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 ERR, 35, 2.4, ZP, SHR-137...
- Page 48 SERVICE KITS Exploded Views Mid Wheel Kit / Ensemble roue 132mm ITEM # PART # DESCRIPTION 2205127 K-WHEEL, CMPLST, MID, UTV HD WHEEL ASSY / ROUE HD ASSEMBLÉE -- 132mm X 50mm WHEEL CAP / CAP DE ROUE HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 Idler Wheel Kit / Ensemble pneu 241mm ITEM # PART #...
- Page 49 SERVICE KITS Exploded Views Outer Rocker Kit / Ensemble stabilisateur mâle ITEM # PART # DESCRIPTION 2205446 K-ROCKER, CMPLST, OUTER, UTV UTV STABILIZER ASSY MALE / STABILISATEUR UTV ASSEMBLÉ, MALE HD WHEEL ASSY / ROUE HD ASSEMBLÉE -- 132mm X 50mm WHEEL CAP / CAP DE ROUE HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 URETHANE CONE, STABILIZER / CÔNE URÉTHANE, STABILISATEUR...
- Page 50 SERVICE KITS Exploded Views Bearing Kit / Ensemble de roulements ITEM # PART # DESCRIPTION 2205871 KIT - BEARINGS, CMPLST, UTV INTERNAL SPACER / ESPACEUR ROULEMENTS BEARING / ROULEMENT -- 6007 BEARING / ROULEMENT -- 6908 SHAFT SEAL / JOINT D'ÉTANCHÉITÉ, ARBRE MOYEU -- 50 x 62 x 10 TC Track Adjuster/Tensioner Kit -- Ens.
- Page 51 SERVICE KITS Exploded Views Front Track Guide Kit / Ensemble guide chenille avant ITEM # PART # DESCRIPTION 2205443 K-HYFAX, CMPLST, FRONT, UTV SDSQWS, #12-24X1.5, ZP TRACK GUIDE FRONT/ GUIDE CHENILLE AVANT Rear Track Guide Kit / Ensemble guide chenille arrière ITEM # PART # DESCRIPTION...
- Page 52 SERVICE KITS Exploded Views Anti-Rotation -- Front (Stabilizing) Arm Kit / Ensemble bras stabilisateur avant ITEM # PART # DESCRIPTION 2205436 KIT- ANTI ROTATION, FRT, UTV 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, DIN6921 X-LONG ROD END / TIGE À...
- Page 53 SERVICE KITS Exploded Views Anti-Rotation -- Rear (Stabilizing) Arm Kit / Ensemble bras stabilisateur arrière ITEM # PART # DESCRIPTION 2205437 KIT- ANTI ROTATION, REAR, UTV LONG ANTI-ROTATION TUBING WELDMENT / TUBE ANTI-ROTATION LONG, SOUDÉ HCS, M10-1.5X80, 10.9, ZP, DIN931 HFSCS, M12-1.75X50, 8.8, ZP, DIN6921 X-LONG ROD END / TIGE À...
- Page 54 SERVICE KITS Exploded Views Hardware kit / Ensemble de quincaillerie ITEM # PART # DESCRIPTION 2205128 K-HDWR, CMPLST, UTV BACK PLATE / PLAQUE DE FIXATION ARRIÈRE STEEL CAP NUT / CAPUCHON DE BOULON HSBS, M6-1X10, 10.9, ZP HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 HCS, M10-1.5X45, 10.9, ZP, TL, DIN931 HFCS, M8-1.25X70, 10.9, ZP, TL, IFI536 HFSCS, M10-1.5X30, 10.9, ZP, DIN6921...
- Page 55 SERVICE KITS Exploded Views Anti-Rotation -- Bracket Kit / Ensemble d’ancrage ITEM # PART # DESCRIPTION 2205448 KIT-ANTIROTATION, BRACKET MAIN PLATE, UNIVERSAL ANTI-ROT. (IS) / PLAQUE PRINCIPALE UNIV. ANTI-ROT. (SI) HCS, M10-1.5X80, 10.9, ZP, DIN931 W, 25X11X2, 8, ZP, USS FNN, M10-1.5, 8, ZP, DIN69261 RETAINER, ANTIROTATION / ANTI-ROTATION, PLAQUE PIVOTANTE Anti-Rotation -- Short bolt Kit / Ensemble boulon court...
- Page 56 Decals (Labels) Kit / Ensemble autocollants (étiquettes) ITEM # PART # DESCRIPTION 2205453 K-DECALS, CMPLST, UTV STICKER - ALIGNMENT / AUTOCOLLANT - ALIGNEMENT STICKER - WARNING / AUTOCOLLANT - AVERTISSEMENT HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS ASSEMBLÉ STICKER / AUTOCOLLANT -- POLARIS UTV...
- Page 57 2 LIPS CAP, 2" O.D. TUBE / BOUCHON 2 LÈVRES, TUBE DIA EXT 2 PO -- LDPE WHEEL CAP / CAP DE ROUE DUST CAP, STABILIZER / CAPUCHON, STABILISATEUR HUB CAP POLARIS ASSY / CAP DE MOYEU POLARIS ASSEMBLÉ Front Track /Chenille avant ITEM #...
- Page 58 SERVICE KITS Exploded Views Rear Track / Chenille arrière ITEM # PART # DESCRIPTION 5414848 TRACK-CMPLST, REAR, UTV Cone Bushing Kit/ERR -- Ensemble cône uréthane/ ERR ITEM # PART # DESCRIPTION 2205462 K- CONE BUSHING, CMPLST, UTV 2205454 ERR, 35, 2.4, ZP, SHR-137...