Polaris 9940495, User Manual

Page 1: ...9940495 2 USER MANUAL ATV TRACK SYSTEM PROSPECTOR PRO 2 0 ...

Page 2: ...f 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 Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or ...

Page 3: ...RUCTIONS 4 SPECIFICATIONS 9 ADJUSTMENTS 10 ANGLE OF ATTACK FRONT SYSTEMS 10 ANGLE OF ATTACK REAR SYSTEMS 11 ALIGNMENT 12 TRACK TENSION 15 TRACKS INSTALLATION DIRECTION 16 STORAGE 16 MAINTENANCE 17 LUBRICATION 20 WEAR 24 ENVIRONMENT 26 PATENTS 26 TROUBLESHOOTING 27 CE DECLARATION OF CONFORMITY 29 EXPLODED VIEWS 30 9940495 VERSION A ...

Page 4: ...d installation guidelines carefully Their content remain applicable after installation of the System This document should be read by everyone operating the vehicle equipped with the System This document is an integral part of the System Pass it along to any new owner of the System Before usage consult the legal authorities of the area where you operate your vehicle equipped with the System to ensu...

Page 5: ...t also be transferred to the new user Moving Parts Hands or fingers caught between moving parts of the equipment present a danger to life or limb Turn motor off before servicing the Track System Maintenance Schedule Follow instructions contained in the User Manual s Maintenance Schedule to ensure safe and long lasting Track System operation TENSIONER WARNING TENSIONER BOLT WARNING If track tension...

Page 6: ...the best traction drive at slow speeds Traction is reduced at faster speeds 6 Moving Track Systems can propel objects Drive slowly when operating near bystanders and when traveling in a group with other vehicles Alert others in your group to the potential for propelled objects in the wake of a track equipped vehicle 7 Always travel at a speed appropriate for your skills and operating conditions Av...

Page 7: ...eed 10 km h maximum real speed A GOOD break in period must be done in a lubricated environment such as water mud snow soft soil sand dust etc A BAD break in period can generate smoke odors of burned rubber as well as plastic deposits on the sprocket and or the frame CAUTION Non compliance with the usage recommendations can lead to a warranty claim refusal PRE USE VERIFICATION CAUTION Before each r...

Page 8: ...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 CAUTION It is advisable to remove the snow from the top of the rear Track Systems and to compact it behind the Systems using your feet to dislodge the track Shovel...

Page 9: ...n DRIVING OVER A STEEP RIDGE CAUTION It is not advisable to attempt to drive over an obstacle such as a tree trunk big rock or steep ridge that could lodge itself between the front and the rear Track Systems and immobilize the vehicle The best option is to bypass this type of obstacle DRIVING OVER AN OBSTACLE WARNING The driver must remain vigilant and cautious at all times Snow and mud can hide d...

Page 10: ...ck Systems CAUTION The towing cable must be attached to the vehicle s frame LOADING AND UNLOADING A VEHICLE IN A TRUCK CAUTION While loading or unloading a vehicle in truck box make sure that the front tracks do not grip the tailgate locking gudgeons to avoid tearing the tracks JUMPING WARNING Jumping with a vehicle equipped with a Track System is not recommended The System was not designed to car...

Page 11: ...nsibility to follow the recommended scheduled maintenance described in this manual DRIVING ACROSS SLOPES EXCEEDING THE ANTI ROTATION STROKE ON ROUGH TERRAIN CAUTION Never exceed anti rotation stroke of front or rear Track Systems System or vehicle failure may occur Always ride on terrain that fully supports the Track System WARNING Driving across slopes can be dangerous On a slope too steep your v...

Page 12: ...ETS ON VEHICLE Installation of a Track System on a vehicle creates offsets in length height and width The offsets are illustrated in the figure below and their dimensions are specified in the accompanying table SPEEDOMETER AND TRIP METER READINGS Our Track System affects the Speedometer and Trip meter readings by approximately 35 depending on the ratio between sprocket and tire size DIMENSION GRAD...

Page 13: ... 3 Position a flat bar on top of rear wheels of front track system and measure from the ground up to flat bar as shown on Figure 4 Figure 4 NOTE Before each measurement temporarily apply light pressure to the front of the track to make sure that it stays flat on the ground Loosen jam nut 1 Adjust length of rod end 2 by rotating the steering limiter support plate on 3 the stabilizing arm Use a 30 m...

Page 14: ...perform the following Stabilizing arm 1 must be attached to rear anchor bracket 2 installed on vehicle Figure 8 NOTE Actual Rear Anchor bracket 2 mounted on vehicle may differ from the one in the illustration Figure 8 Loosen anti rotation bracket bolts 3 to allow the anti rotation retainer 4 to rotate on its axis See Figure 9 Figure 9 Loosen jam nut 5 Turn stabilizing arm 1 to adjust length of rod...

Page 15: ...after re installing your wheels the handling caracteristics of the vehicle will differ from those produced by Track Systems ALIGNMENT 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 NOTE Every time the measurement has to be taken drive in reverse then drive forward again on about 3 meters 10 f...

Page 16: ...adjustment is complete See Figure 14 NOTE Starting with an open alignment setting provides a higher degree of precision of the adjustment CAUTION Before loosening coupling rod nuts 1 on the vehicle s steering system remember that some nuts have reverse threads Make sure to unlock the nut in the proper rotational direction ATV Figure 14 NOTE Once parallelism of front Systems is set verify once more...

Page 17: ... the front Track Systems See figures 15 16 and 17 Figure 15 Figure 16 Distance between front wheels Figure 17 Measure B Measure the distance inside the rear Ø202 mm wheels on the front Track Systems See figures 18 19 and 20 Figure 18 Figure 19 Distance between rear wheels Figure 20 ...

Page 18: ...ded Lower rubber track tension provides better traction a smoother ride and better fuel economy Final Check Ride at slow speed on a distance of about 1 5 km 1 mile Re adjust as required NOTE In applications where installation of traction studs is needed the threaded portion of the stud to be screwed in the track lug should not exceed 3 4 inch 19 mm in length NOTICE Rubber Track warranty coverage i...

Page 19: ...he maintenance chart of page 18 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 necessary to perform the recommended tasks contained in the maintenance schedule The following service steps must be performed before storage Clean Track system Inspect Track system comple...

Page 20: ...rformance and maximum durability please refer to the maintenance chart below For more details on the maintenance program consult the Maintenance specifications on page 18 and page 19 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 MAINTENANCE INITIAL INTERVALS FIRST USE EVERY 25A 40B HRS EVERY 50A 75B H...

Page 21: ...e Track Systems installed Follow the manufacturer s recommendations Refer to the Alignment section on page 12 Bolt Torque Check the torque of critical bolts identified in the exploded views of the system Refer to the central pages of the User Manual CAUTION Comply with the tightening torque recommendations and use a thread locker product if you come across a bolt that is not tightened to the manuf...

Page 22: ...ear section in the User Manual on page 25 Cracks Visually inspect frames for presence of cracks or defects that can impair proper operation of the Track System Replace components if damaged Sprockets Wear Check wear of sprockets on the Systems Replace if wear is too great Refer to Wear in the Maintenance section on page 26 Anti rotation Lubrication The maintenance chart recommends cleaning and lub...

Page 23: ...20 MAINTENANCE LUBRICATION A WHEEL SEALS SHAFTS B WHEELS BEARINGS C HUB SEAL D HUB HOUSING E HUB SPEED SLEEVE F TRACK TENSIONER G ANTI ROTATION ARM ...

Page 24: ... wheel shaft at position shown below NOTE Installing new wheel seals is recommended when lubricating these components Apply evenly 3 to 3 5 cc of grease all around the wheel seal s V shaped groove NOTE V shaped groove must be filled with grease all around WHEEL SEAL LUBRICATION narrow Ø134 mm wheels Install new seal on clean dry wheel shaft at mid point on bearing seat NOTE Installing new wheel se...

Page 25: ...aring life Unbolt wheel from frame and carefully remove exterior bearing seal 1 of both bearings Clean off old lubricant and pack with new grease Lastly re install seals over matching bearings CAUTION Take special care to avoid damaging the bearing seals when you remove and reinstall them REFERENCE C HUB BEARING SEAL LUBRICATION Apply evenly 1 5 to 2 cc of grease between the hub seal lips and on i...

Page 26: ... of grease over the entire width and circumference of the hub Speed Sleeve REFERENCE F FRAME TUBING TENSIONER SIDE Slide the tensioner to its furthest point out Apply evenly a thin coat of grease oil or spray lubricant on the outside of the tensioner tubing over the entire circumference 360 NOTE Application of lubricant on the tensioner tubing prevents corrosion inside the frame Lubrication allows...

Page 27: ...isassemble rod end assembly and rotate ball in its seat to distribute lubricant Track Wear of external profile impacts track performance directly Important wear on profiles means less traction Replace track if you notice a significant loss of performance Verify internal and external rolling path profiles and driving lugs Presence of tears perforations or delamination in these places can render the...

Page 28: ... coating is worn away and wheel must be replaced See Figure 33 Figure 33 Urethane cones Stabilizers Check condition of urethane cones mounted on stabilizer shaft Replace both of them if they show oval wear on the bore cracks or are deformed See Figure 34 Figure 34 Track guide Verify wear on Track guide by measuring width of guide rails If rail dimensions illustrated in Figure 35 are less than 5 mm...

Page 29: ...nditions ENVIRONMENT Track Systems are made of varied materials steel aluminum rubber plastic grease oil used by the manufacturer Please recycle reuse or dispose of components at appropriate depot facilities when Track Systems come to the end of 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 CA 2 822 562 CA 2 825 ...

Page 30: ...lign Track System if needed Check wear on wheels track guide and track drive lugs Presence of dirt between wheel hub and track system hub could cause incorrect seating of mating surfaces when installing track system Remove system and clean contact surfaces between hubs Damaged Hub or wheel bearing Replace damaged bearing Wheel Hub or track system hub deformed following an impact or abusive use Rep...

Page 31: ...ce Remove ice snow build up on wheels Clear all compacted snow between frame and wheels Snow infiltration in vehicle s air intake or clutch system Remove snow and contact dealer immediately to fix the situation Partial or total derailing Severe wear on one or several components Check tensioner alignment Check wear on track guide inside driving lugs and wheels Track tension too low Adjust track ten...

Page 32: ... THAT THE PRODUCT SERIES PRODUCT 3RODULV 3URVSHFWRU 3UR CUSTOMER IS IN CONFORMITY WITH THE FOLLOWING STANDARDS 180 5 7 7 7 3UHSDUDWLRQ RI LQIRUPDWLRQ IRU XVH RI SURGXFWV 62 6DIHW RI 0DFKLQHU 62 RQIRUPLW VVHVVPHQW AND IN CONFORMITY WITH THE FOLLOWING EC DIRECTIVE 180 5 7 7 7 6DIHW RI PDFKLQHU GLUHFWLYHV DONE AT Shawinigan Québec Canada PERSON IN CHARGE TITLE SIGNATURE DATE DECLARATION OF CONFORMITY...

Page 33: ...V 7 5 2 5 ITEM PART DESCRIPTION QTY A 2205433 K SPROCKET CMPLST 18 TOOTH 1 1 SPROCKET CMPLST XP 18 TOOTH 1 2 HFSCS M10 1 5X30 10 9 ZP TL DIN6921 4 72548 1P IW OEV 7 5 2 5 7 7 ITEM PART DESCRIPTION QTY B 2205434 K HUB CMPLST 13mm 1 1 HUB CMPLST XP 13mm ASSY 1 2 HFSCS M10 1 5X30 10 9 ZP TL DIN6921 4 3 2205454 ERR 35 2 4 ZP SHR 137 1 ...

Page 34: ...435 K HUB CMPLST 32mm 1 1 HUB CMPLST XP 32mm ASSY 1 2 HFSCS M10 1 5X30 10 9 ZP TL DIN6921 4 3 2205454 ERR 35 2 4 ZP SHR 137 1 D TORQUE 30 Nm 22 ft lbs THREAD LOCKER THREAD 1 2 3 4 ITEM PART DESCRIPTION QTY D 2205122 K WHEEL CMPLST MID ATV 1 1 WHEEL ROUE ATV 134 MM 1 2 WHEEL CAP CAP DE ROUE 1 3 HCSW M10 1 5X25 8 8 ZP TL DIN933 1 4 WHEEL SEAL JOINT D ÉTANCHÉITÉ 25 ID X 42 OD 1 ...

Page 35: ...ECTION WHEEL ASSY 134MM ROUE INJECTION ASS 1 2 WHEEL CAP CAP DE ROUE 1 3 HCSW M10 1 5X25 8 8 ZP TL DIN933 1 4 SHAFT SEAL JOINT D ÉTANCHÉITÉ DE ROUE 1 72548 1P IW OEV 7 5 2 5 7 5 ITEM PART DESCRIPTION QTY F 2209515 K WHEEL CMPLST IDLER ATV 2 0 1 1 202MM INJECTION WHEEL ASSY 202MM ROUE INJECTION ASS 1 2 WHEEL CAP CAP DE ROUE 1 3 HCSW M10 1 5X25 8 8 ZP TL DIN933 1 4 SHAFT SEAL JOINT D ÉTANCHÉITÉ DE R...

Page 36: ... QTY G 2205123 KIT BEARINGS CMPLST ATV 1 1 INTERNAL SPACER ESPACEUR ROULEMENTS 1 2 STANDARD BEARING ROULEMENT À BILLES STANDARD 2 3 SHAFT SEAL JOINT D ÉTANCHÉITÉ ARBRE MOYEU 50 x 62 x 10 1 H 1 2 ITEM PART DESCRIPTION QTY H 2209519 K GUIDE CMPLST ATV 2 0 S KIT GUIDE ATV 1 1 SDSQWS 12 24X1 5 ZP 4 2 TRACK GUIDE GUIDE DE CHENILLE 1 ...

Page 37: ... IFI536 1 5 HFSCS M10 1 5X30 10 9 ZP TL DIN 6921 6 6 SDSQWS 12 24X1 5 ZP 4 7 SLIDE BUSHING ESPACEUR 1 8 TENSIONER BUSHING COUSSINET TENDEUR 1 9 W 7 16X1 0X0 072 8 ZP USS 2 10 W 3 8X1 1 4 0 120 ZP 2 11 FNN M8 1 25 10 ZP DIN6926 1 12 WHEEL AXLE STABILIZER AXE DE ROUE STABILISATEUR 2 13 AXLE SHAFT DAMPER AXE ARBRE AMORTISSEUR 1 14 TRACK TENSIONER NUTS ASS Y TENDEUR CHENILL ÉCR ASS 1 15 URETHANE CONE ...

Page 38: ...31 1 3 HFSCS M12 1 75X50 8 8 ZP FULL THREAD 1 4 X LONG ROD END TIGE À OEIL X LONGUE 1 5 BUSHING SPACER 3 8 1 6 T BUSHING BAGUE EN T 1 7 W 7 16X1 0X0 072 8 ZP USS 1 8 FNN M10 1 5 8 ZP DIN6926 9 COMPRESSION SPRING RESSORT COMPRESSION 138 285 LBS IN 10 RUBBER DAMPER AMORTISSEUR DE CAOUTCHOUC K TORQUE 70 Nm 52 ft lbs THREAD LOCKER 1 2 3 4 ITEM PART DESCRIPTION QTY K 2205449 K HDWR ANTI ROTATION SHORT ...

Page 39: ...CMPLST SHT ATV 2 0 TENDEUR CHENILLE COURT 1 1 TENSIONER BLACK TENDEUR NOIR 1 2 FRAME TAIL PLASTIC CAP CAP DE QUEUE DE CADRE 1 3 HFCS M8 1 25X80 10 9 ZP IFI536 1 4 SLIDE BUSHING ESPACEUR 1 5 TENSIONER BUSHING COUSSINET TENSIONNEUR 1 6 FNN M8 1 25 10 ZP DIN6926 1 7 TENSIONER ROD HEX NUT ASS Y ENS TIGE TEND ÉCROU HEX 1 8 STICKER LOOSEN AUTOCOLLANT DESSERRER 1 ...

Page 40: ...PLST LNG ATV 2 0 TENDEUR CHENILLE LONG 1 1 TENSIONER BLACK TENDEUR NOIR 1 2 FRAME TAIL PLASTIC CAP CAP DE QUEUE DE CADRE 1 3 HFCS M8 1 25X80 10 9 ZP IFI536 1 4 SLIDE BUSHING ESPACEUR 1 5 TENSIONER BUSHING COUSSINET TENSIONNEUR 1 6 FNN M8 1 25 10 ZP DIN6926 1 7 TENSIONER ROD HEX NUT ASS Y ENS TIGE TEND ÉCROU HEX 1 8 STICKER LOOSEN AUTOCOLLANT DESSERRER 1 ...

Page 41: ... 4 0 120 ZP 1 4 WHEEL AXLE STABILIZER AXE DE ROUE STABILISATEUR 1 5 SHAFT SEAL JOINT DE ROUE 3 6 URETHANE CONE STABILIZER CÔNE URÉTHANE STABILISATEUR 2 O 5 1 2 3 4 6 TORQUE 70 Nm 52 ft lbs THREAD LOCKER ITEM PART DESCRIPTION QTY O 2209517 K STABILIZER AXLE REAR ATV 2 0 1 1 HCS M10 1 5X25 10 9 ZP TL DIN933 2 2 WASHER RONDELLE 3 8X1 1 4 0 120 ZP 2 3 WHEEL AXLE STABILIZER AXE DE ROUE STABILISATEUR 2 ...

Page 42: ...25X80 10 9 ZP IFI536 1 8 SDSQWS 12 24X1 5 ZP 4 9 SLIDE BUSHING ESPACEUR 1 10 TENSIONER BUSHING COUSSINET TENDEUR 1 11 FNN M8 1 25 10 ZP DIN6926 1 12 TENSIONER ROD NUTS ASS TIGE TENDEUR ÉCROUS ASS 1 13 STICKER DO NOT LOOSEN DÉCALQUE NE PAS DESSERRER 1 14 STICKER FRONT RIGHT PICTOGRAM DÉCALQUE PICTOGRAMME AVD 1 15 STICKER WARNING AUTOCOLLANT AVERTISSEMENT 1 16 STICKER POLARIS ATV 2 0 DÉCALQUE POLARI...

Page 43: ...25X80 10 9 ZP IFI536 1 8 SDSQWS 12 24X1 5 ZP 4 9 SLIDE BUSHING ESPACEUR 1 10 TENSIONER BUSHING COUSSINET TENDEUR 1 11 FNN M8 1 25 10 ZP DIN6926 1 12 TENSIONER ROD NUTS ASS TIGE TENDEUR ÉCROUS ASS 1 13 STICKER DO NOT LOOSEN DÉCALQUE NE PAS DESSERRER 1 14 STICKER FRONT LEFT PICTOGRAM DÉCALQUE PICTOGRAMME AVG 1 15 STICKER WARNING AUTOCOLLANT AVERTISSEMENT 1 16 STICKER POLARIS ATV 2 0 DÉCALQUE POLARIS...

Page 44: ...6 1 7 SDSQWS 12 24X1 5 ZP 4 8 SLIDE BUSHING ESPACEUR 1 9 TENSIONER BUSHING COUSSINET TENDEUR 1 10 FNN M8 1 25 10 ZP DIN6926 1 11 TENSIONER ROD NUTS ASS TIGE TENDEUR ÉCROUS ASS 1 12 STICKER DO NOT LOOSEN DÉCALQUE NE PAS DESSERRER 1 13 STICKER REAR RIGHT PICTOGRAM DÉCALQUE PICTOGRAMME ARD 1 14 STICKER WARNING AUTOCOLLANT AVERTISSEMENT 1 15 STICKER POLARIS ATV 2 0 DÉCALQUE POLARIS ATV 2 0 1 16 TRACK ...

Page 45: ...6 1 7 SDSQWS 12 24X1 5 ZP 4 8 SLIDE BUSHING ESPACEUR 1 9 TENSIONER BUSHING COUSSINET TENDEUR 1 10 FNN M8 1 25 10 ZP DIN6926 1 11 TENSIONER ROD NUTS ASS TIGE TENDEUR ÉCROUS ASS 1 12 STICKER DO NOT LOOSEN DÉCALQUE NE PAS DESSERRER 1 13 STICKER REAR LEFT PICTOGRAM DÉCALQUE PICTOGRAMME ARG 1 14 STICKER WARNING AUTOCOLLANT AVERTISSEMENT 1 15 STICKER POLARIS ATV 2 0 DÉCALQUE POLARIS ATV 2 0 1 16 TRACK G...

Page 46: ...IROTATION BRACKET S KIT ANTIROT SUSP IND 1 1 BACK PLATE PLAQUE DE FIXATION 1 2 ANTI ROTATION BRACKET IND SUSP ATTACHE ANTI ROTATION SI 1 3 HCSW M10 1 5X25 8 8 ZP TL DIN933 1 4 HFSCS M10 1 5X30 10 9 ZP TL DIN 6921 2 5 W 7 16X1 0X0 072 8 ZP USS 2 6 W 3 8X1 1 4 0 120 ZP 1 7 NN M10 1 5 ZP 8 DIN982 1 U V ITEM PART DESCRIPTION QTY U 2205462 K CONE BUSHING CMPLST UTV CÔNE CAOUTCHOUC 1 V 2205454 ERR 35 2 ...

Page 47: ... X ITEM PART DESCRIPTION QTY X 2209518 K DECAL CMPLST ATV 2 0 S KIT DECALQUE POLARIS ATV 2 0 1 1 STICKER DO NOT LOOSEN DÉCALQUE NE PAS DESSERRER 1 2 STICKER FRONT LEFT PICTOGRAM DÉCALQUE PICTOGRAMME AVG 1 3 STICKER FRONT RIGHT PICTOGRAM DÉCALQUE PICTOGRAMME AVD 1 4 STICKER REAR LEFT PICTOGRAM DÉCALQUE PICTOGRAMME ARG 1 5 STICKER REAR RIGHT PICTOGRAM DÉCALQUE PICTOGRAMME ARD 1 6 STICKER WARNING AUT...

Page 48: ...45 EXPLODED VIEWS Rear Track Chenille arrière Front Track Chenille avant z ITEM PART DESCRIPTION QTY Y 5414841 TRACK CMPLST REAR ATV 1 ITEM PART DESCRIPTION QTY Z 5414840 TRACK CMPLST FRONT ATV 1 ...