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Polaris PROSPECTOR PRO 2.0 User Manual
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Polaris PROSPECTOR PRO 2.0 User Manual

Atv track kit
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ATV TRACK SYSTEM
PROSPECTOR PRO 2.0
2 USER MANUAL
9940495

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Summary of Contents for Polaris PROSPECTOR PRO 2.0

  • Page 1 ATV TRACK SYSTEM PROSPECTOR PRO 2.0 2 USER MANUAL 9940495...
  • Page 2 Industries Inc. LOCTITE® is a registered trademark of Henkel Corporation. Copyright 2021 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

    TABLE OF CONTENTS INTRODUCTION ................1 SYMBOLS AND SIGNAL WORDS .

  • Page 4: Introduction

    INTRODUCTION INTRODUCTION • Before usage, consult the legal authorities of the area where you operate your vehicle equipped with the System to ensure that all applicable laws and regulations are observed. SYMBOLS AND SIGNAL WORDS • ATV and SxS Track Systems are designed to This guide uses the following signal words and reduce ground pressure and increase vehicle symbols to emphasize particular information:...

  • Page 5: Safety

    CAUTION: Do not remove the warning sticker from the frame. If a sticker is damaged, have it replaced assembly bolt under any circumstance. The bolt is at an authorized Polaris dealer. used to assemble and align the tensioner with the frame. Tensioner re-alignment is necessary if this bolt is loosened.
  • Page 6 SAFETY OPERATION 11. When driving in snow, allow for a greater braking distance. Periodically apply the brakes while driving to prevent ice buildup on brake Safe Operation Practices components. 12. Never operate on a frozen body of water. 1. Read and understand this user manual and all warning and instruction labels before operating a track-equipped vehicle.

  • Page 7: Operating Instructions

    OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS • A BAD break-in period can generate smoke, odors of burned rubber as well as plastic deposits on the sprocket and/or the frame. HINTS AND TIPS • Before leaving for an excursion, make sure to bring with you the following: 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, and 19 mm wrenches and WARNING sockets, an ax, a shovel, a tow cable, a lifting...
  • Page 8 OPERATING INSTRUCTIONS STEEP DESCENTS DESCENDING AND BEING STUCK IN REVERSE CAUTION: It is not advisable to change direction CAUTION: If the rear Track Systems get stuck in the during steep descents. This can lead to a serious snow, avoid moving or towing the vehicle in reverse malfunction of the vehicle’s steering system and to ease it from its position, as this could lead to a Track Systems.
  • Page 9 OPERATING INSTRUCTIONS DRIVING OVER AN OBSTACLE TALLER DRIVING OVER A STEEP RIDGE THAN 30 cm [12 in] CAUTION: It is not advisable to attempt to drive over an obstacle, such as a tree trunk, big rock or steep CAUTION: It is not advisable to attempt to drive ridge that could lodge itself between the front and over an obstacle taller than 30 cm [12 in], such as a the rear Track Systems and immobilize the vehicle.
  • Page 10 OPERATING INSTRUCTIONS TOWING A VEHICLE OUT OF THE SNOW LOADING AND UNLOADING A VEHICLE IN A TRUCK CAUTION: If your vehicle must be towed out of the snow, never tow it in the direction in which you CAUTION: While loading or unloading a vehicle in were riding when the vehicle got stuck.
  • Page 11 OPERATING INSTRUCTIONS TRACK SYSTEM OPERATING IN WATER OR MUD CAUTION: If the Track System is used in wet conditions, submerged in water and/or mud, make sure to consult the Track System’s maintenance chart and to observe the maintenance intervals indicated in this manual related to commercial, industrial and abrasive conditions use.

  • Page 12: Specifications

    OFFSET equivalent) at indicated places in the exploded (LENGTH) 27 in (686 mm) REAR views of the system. OFFSET 7 in (178 mm) POLARIS (WIDTH) OFFSET 24 in 3 in (76 mm) ORIGINAL TIRE: (HEIGHT) SPEEDOMETER AND TRIP METER READINGS...

  • Page 13: Adjustments

    ADJUSTMENTS ADJUSTMENTS NOTE : Before each measurement, temporarily apply light pressure to the front of the track to make sure that it stays flat on the ground. CAUTION: After the first use of the vehicle, the adjustment settings (track tension, alignment and •...

  • Page 14: Angle Of Attack - Rear Systems

    ADJUSTMENTS NOTE: Once the angle of attack on the front systems • Loosen anti-rotation bracket bolts (3) to allow is set, verify once again to confirm the the anti-rotation retainer (4) to rotate on its axis. adjustment. See Figure 9. Figure 7 Figure 9 •...

  • Page 15: Alignment

    ADJUSTMENTS ALIGNMENT • Re-tighten anti-rotation bracket bolts (3) to 50 N•m [37 lb-ft] of torque. See Figure 12. Parallelism must be adjusted with the ATV on the ground, driving the vehicle forward about 3 meters [10 ft.] and measuring toe–in distance. Refer to Figure 13.
  • Page 16 ADJUSTMENTS Adjustment Method To adjust the vehicle’s steering system, first loosen coupling rod nuts (1), then screw or unscrew the coupling rod (2) an equal number of revolutions on both sides of the vehicle. Re- tighten nuts when adjustment is complete. See Figure 14.
  • Page 17 ADJUSTMENTS Measure A: Measure the distance inside the front Measure B: Measure the distance inside the rear Ø202 mm wheels on the front Track Systems. Ø202 mm wheels on the front Track Systems. See See figures 15, 16 and 17. figures 18, 19 and 20.

  • Page 18: Track Tension

    ADJUSTMENTS TRACK TENSION • Measure and adjust track tension using a tension testing tool and a flat bar. Apply the recommended pressure (3) to measure track deflection (4). See Figure 24. WARNING The tensioner assembly bolt must never be loosened while adjusting the track tension. This bolt is designed for assembly and alignment of the tensioner with the frame.

  • Page 19: Tracks - Installation Direction

    STORAGE TRACKS - INSTALLATION DIRECTION Before storing the Track System, it is important to perform the recommended annual maintenance Front track: can be installed in both direction. tasks. Refer to the maintenance chart of page 18, Figure 25. section Intervals - column 200 Hrs / Annual. To avoid deterioration of mechanical components due to potential prolonged exposition to water, sand, salt or other similar contaminant, it is...

  • Page 20: Maintenance

    MAINTENANCE MAINTENANCE CAUTION: Do not use a brake cleaning solvent to WARNING clean the Track System. This may damage sealing components and stickers. Do not insert hands or feet into or near the System unless the engine is off, and the vehicle is The maintenance schedule has been established stopped with the security brake engaged.
  • Page 21 MAINTENANCE CAUTION: Some of the repair or maintenance • Bolt Torque: Check the torque of critical bolts tasks require petroleum-based identified in the exploded views of the system. products, such as oils or greases, that should not Refer to the central pages of the User Manual. be handled directly with unprotected hands.
  • Page 22 MAINTENANCE Frame • Cracked or bent parts: Visually inspect anti- rotation arms for presence of cracked or bent parts that can impair proper functioning. • Hub Bearings: Check hub bearings for Replace components if damaged. restriction, noise or abnormal play in rotation. Bearings must absolutely be replaced if they present a defect.

  • Page 23: Lubrication

    MAINTENANCE LUBRICATION WHEEL SEALS & SHAFTS WHEELS & BEARINGS HUB SEAL HUB HOUSING HUB - SPEED SLEEVE TRACK TENSIONER ANTI-ROTATION ARM...
  • Page 24 MAINTENANCE LUBRICATION WHEEL SEAL LUBRICATION (narrow Ø134 mm wheels) The maintenance chart on page 17 includes Install new seal on clean, dry wheel shaft at mid- lubrication maintenance to perform on the point on bearing seat. Track Systems. Refer following recommendations for optimal lubrication.
  • Page 25 MAINTENANCE WHEEL SHAFT LUBRICATION Unbolt wheel from frame and carefully remove exterior bearing seal (1) of both bearings. Clean Apply evenly 1 to 1.5 cc of grease on the wheel off old lubricant and pack with new grease. Lastly, shaft, over the entire circumference (360°) and re-install seals over matching bearings.
  • Page 26 MAINTENANCE REFERENCE “D” REFERENCE “F” HUB LUBRICATION FRAME TUBING - TENSIONER SIDE Following replacement of hub bearings and/or re- Slide the tensioner to its furthest point out. Apply installation of hub, pour 25 cc of oil through hole evenly a thin coat of grease, oil or spray lubricant on top of hub housing intended for this purpose.

  • Page 27: Wear

    MAINTENANCE WEAR Track Wear external profile impacts track Rubber dampers (Stabilizing arms) performance directly. Important wear on profiles means less traction. Replace track if you notice a Check wear and damage on rubber dampers significant loss of performance. Verify internal and mounted on the stabilizing arms.
  • Page 28 MAINTENANCE Wheels Urethane cones (Stabilizers) (Ø134mm - narrow) Check condition of urethane cones mounted on Verify wear also on narrow Ø134mm wheels stabilizer shaft. Replace both of them, if they located on the inside of rear Track System units, show oval wear on the bore, cracks or are especially on interior guidance strip.

  • Page 29: Environment

    Track Systems come to the end of efficiency and reduce System performance. their life. PATENTS The Polaris® Prospector Pro® Track System is covered by the following patents: • CA 2 405 908 • CA 2 493 181 • CA 147 901 •...

  • Page 30: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING...
  • Page 31 TROUBLESHOOTING...

  • Page 32: Ce'' Declaration Of Conformity

    ’’CE’’ DECLARATION OF CONFORMITY ’’CE’’ DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY MANUFACTURER : Camso Inc. ADDRESS : 4162, rue Burrill, Local A Shawinigan (Québec), Canada G9N 0C3 PHONE : FAX : WEB SITE : www.camso.co HEREBY DECLARE THAT THE PRODUCT SERIES: PRODUCT : CUSTOMER : IS IN CONFORMITY WITH THE FOLLOWING STANDARDS:...

  • Page 33: Exploded Views

    EXPLODED VIEWS EXPLODED VIEWS 18-Tooth Sprocket Kit / Ensemble barbotin 18 dents ITEM # PART # DESCRIPTION 2205433 K-SPROCKET, CMPLST, 18 TOOTH SPROCKET-CMPLST XP, 18 TOOTH HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 13mm Hub Kit / Ensemble moyeu 13 mm ITEM # PART # DESCRIPTION...
  • Page 34 EXPLODED VIEWS 32mm Hub Kit / Ensemble moyeu 32 mm TORQUE 90 Nm [66 ft-lbs] + THREAD LOCKER ITEM # PART # DESCRIPTION 2205435 K-HUB, CMPLST, 32mm HUB-CMPLST XP 32mm, ASSY HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN6921 2205454 ERR, 35, 2.4, ZP, SHR-137 Narrow Mid Wheel Kit / Ensemble roue 134mm - étroite TORQUE 30 Nm [22 ft-lbs] + THREAD LOCKER...
  • Page 35 EXPLODED VIEWS Wide Mid Wheel Kit / Ensemble roue 134mm - large ITEM # PART # DESCRIPTION 2209514 K-WHEEL, CMPLST, MID, ATV 2.0 134MM INJECTION WHEEL, ASSY / 134MM ROUE INJECTION, ASS. WHEEL CAP / CAP DE ROUE HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 SHAFT SEAL / JOINT D'ÉTANCHÉITÉ...
  • Page 36 EXPLODED VIEWS Bearing Kit / Ensemble de roulements ITEM PART # DESCRIPTION 2205123 KIT - BEARINGS, CMPLST, ATV INTERNAL SPACER / ESPACEUR ROULEMENTS STANDARD BEARING / ROULEMENT À BILLES STANDARD SHAFT SEAL / JOINT D'ÉTANCHÉITÉ, ARBRE MOYEU -- 50 x 62 x 10 Track Guide Kit / Ensemble guide de chenille ITEM # PART #...
  • Page 37 EXPLODED VIEWS Hardware Kit / Ensemble de quincaillerie ITEM # PART # DESCRIPTION 2209505 K-HDWR, CMPLST, ATV 2.0 / S-KIT QUINCAILLERIE BACKPLATE / PLAQUE DE FIXATION ARRIÈRE HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 HCS, M10-1.5X25, 10.9, ZP, TL, DIN933 HFCS, M8-1.25X80, 10.9, ZP, IFI536 HFSCS,M10-1.5X30,10.9,ZP,TL,DIN 6921 SDSQWS, #12-24X1.5, ZP SLIDE BUSHING / ESPACEUR...
  • Page 38 EXPLODED VIEWS Anti-Rotation (Stablizing) Arm Kit / Ensemble bras stabilisateur YELLOW LINE THIS END TORQUE 75 Nm [55 ft. lbs.] ITEM PART # DESCRIPTION 2209506 K-STAB ROD, CMPLST, ATV 2.0 / S-KIT BRAS STABILISATEUR - ATV SHORT ANTI-ROTATION ROD / TIGE ANTI-ROTATION COURTE HCS, M10-1.5X60, 10.9, ZP, DIN931 HFSCS, M12-1.75X50, 8.8, ZP, FULL THREAD X-LONG ROD END / TIGE À...
  • Page 39 EXPLODED VIEWS Short Track Tensioner / Tendeur de chenille court TORQUE 40 Nm [30 ft-lbs] + THREAD LOCKER ITEM # PART # DESCRIPTION 2209511 K-TENSIONER, CMPLST, SHT, ATV 2.0 / TENDEUR CHENILLE COURT TENSIONER - BLACK / TENDEUR NOIR FRAME, TAIL PLASTIC CAP / CAP DE QUEUE DE CADRE HFCS, M8-1.25X80, 10.9, ZP, IFI536 SLIDE BUSHING / ESPACEUR TENSIONER BUSHING / COUSSINET TENSIONNEUR...
  • Page 40 EXPLODED VIEWS Long Track Tensioner / Tendeur de chenille long TORQUE 40 Nm [30 ft-lbs] + THREAD LOCKER ITEM # PART # DESCRIPTION 2209512 K-TENSIONER, CMPLST, LNG, ATV 2.0 / TENDEUR CHENILLE LONG TENSIONER - BLACK / TENDEUR NOIR FRAME, TAIL PLASTIC CAP / CAP DE QUEUE DE CADRE HFCS, M8-1.25X80, 10.9, ZP, IFI536 SLIDE BUSHING / ESPACEUR TENSIONER BUSHING / COUSSINET TENSIONNEUR...

  • Page 41: Hcsw, M10-1.5X25, 8.8, Zp, Tl, Din933

    EXPLODED VIEWS Stabilizer Kit / Stabilisateur assemblé TORQUE 70 Nm [52 ft-lbs] + THREAD LOCKER ITEM # PART # DESCRIPTION 2209513 K-STABILIZER, CMPLST, ATV 2.0 STABILIZER ASSY / STABILISATEUR ASSEMBLÉ HCS, M10-1.5X25, 10.9, ZP, TL, DIN933 WASHER / RONDELLE -- 3/8X1-1/4, 0.120, ZP WHEEL AXLE, STABILIZER / AXE DE ROUE, STABILISATEUR SHAFT SEAL / JOINT DE ROUE URETHANE CONE, STABILIZER / CÔNE URÉTHANE, STABILISATEUR...
  • Page 42 STICKER - DO NOT LOOSEN / DÉCALQUE - NE PAS DESSERRER STICKER, FRONT RIGHT PICTOGRAM / DÉCALQUE PICTOGRAMME AVD STICKER WARNING / AUTOCOLLANT AVERTISSEMENT STICKER - POLARIS ATV 2.0 / DÉCALQUE - POLARIS ATV 2.0 TRACK GUIDE / GUIDE DE CHENILLE -- ATV T4S HHP, M10-1 2205454 ERR, 35, 2.4, ZP, SHR-137...

  • Page 43: Hfcs, M8-1.25X80, 10.9, Zp, Ifi536

    STICKER - DO NOT LOOSEN / DÉCALQUE - NE PAS DESSERRER STICKER, FRONT LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME AVG STICKER WARNING / AUTOCOLLANT AVERTISSEMENT STICKER - POLARIS ATV 2.0 / DÉCALQUE - POLARIS ATV 2.0 TRACK GUIDE / GUIDE DE CHENILLE -- ATV T4S HHP, M10-1 2205454 ERR, 35, 2.4, ZP, SHR-137...
  • Page 44 STICKER - DO NOT LOOSEN / DÉCALQUE - NE PAS DESSERRER STICKER, REAR RIGHT PICTOGRAM / DÉCALQUE PICTOGRAMME ARD STICKER WARNING / AUTOCOLLANT AVERTISSEMENT STICKER - POLARIS ATV 2.0 / DÉCALQUE - POLARIS ATV 2.0 TRACK GUIDE / GUIDE DE CHENILLE -- ATV T4S HHP, M10-1 2205454 ERR, 35, 2.4, ZP, SHR-137...
  • Page 45 STICKER - DO NOT LOOSEN / DÉCALQUE - NE PAS DESSERRER STICKER, REAR LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME ARG STICKER WARNING / AUTOCOLLANT AVERTISSEMENT STICKER - POLARIS ATV 2.0 / DÉCALQUE - POLARIS ATV 2.0 TRACK GUIDE / GUIDE DE CHENILLE -- ATV T4S HHP, M10-1 2205454 ERR, 35, 2.4, ZP, SHR-137...
  • Page 46 EXPLODED VIEWS Anti-Rotation Bracket Kit / Ensemble attache antirotation ITEM PART # DESCRIPTION 2205448 KIT-ANTIROTATION, BRACKET / S-KIT ANTIROT. SUSP. IND. BACK PLATE / PLAQUE DE FIXATION ANTI-ROTATION BRACKET IND SUSP / ATTACHE ANTI-ROTATION SI HCSW, M10-1.5X25, 8.8, ZP, TL, DIN933 HFSCS, M10-1.5X30, 10.9, ZP, TL, DIN 6921 W, 7/16X1.0X0.072, 8, ZP, USS W,3/8X1-1/4,0.120,ZP...

  • Page 47: Hhp, M10-1

    PART # DESCRIPTION 2209518 K- DECAL, CMPLST, ATV 2.0 / S-KIT DECALQUE, POLARIS ATV 2.0 STICKER - DO NOT LOOSEN / DÉCALQUE - NE PAS DESSERRER STICKER, FRONT LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME AVG STICKER, FRONT RIGHT PICTOGRAM / DÉCALQUE PICTOGRAMME AVD STICKER, REAR LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME ARG...
  • Page 48 EXPLODED VIEWS Rear Track / Chenille arrière ITEM PART # DESCRIPTION 5414841 TRACK-CMPLST, REAR, ATV Front Track / Chenille avant ITEM PART # DESCRIPTION 5414840 TRACK-CMPLST, FRONT, ATV...

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9940495