Polaris PROSPECTOR PRO User manual

UTV TRACK SYSTEM
PROSPECTOR PRO
2016 USER MANUAL
9925638

2
PROSPECTOR PRO®
UTV Track Kit User Manual
NOTICE: Driveline and power train warranty coverage under the POLARIS
Extended Service Contract (if purchased) is terminated upon
installation of a track kit.
POLARIS® and PROSPECTOR PRO® are registered trademarks of POLARIS
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. 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 procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this product are in English. Other languages are provided as
translations of the original instructions.
Printed in Canada
POLARIS PROSPECTOR PRO UTV Track Kit User Manual

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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation, Removal, Re-Installation . . . . . . . 15
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rubber Track Installation . . . . . . . . . . . . . . . . 26
Track System Break-In . . . . . . . . . . . . . . . . . . . 27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 40
“CE” Declaration of Conformity . . . . . . . . . . 41
Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
P/N 9925638 - VERSION D

INTRODUCTION
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INTRODUCTION
The following signal words and symbols appear in this manual and on
safety labels. Your safety is involved when these words and symbolsare
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.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could
result in minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in
order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS
to be taken to avoid a hazard.

INTRODUCTION
5
Failure to heed the warnings and safety precautions contained in this
manual can result in severe injury or death. A collision or rollover can
occur quickly, even during routine maneuvers like turning, or driving on
hills or over obstacles, if you fail to take proper precautions.
• 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.
• Every user must read this user manual. Understand all safety
warnings, precautions and operating procedures before operating a
POLARIS vehicle equipped with the 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.
• Always follow all inspection and maintenance procedures described
in this user manual and in the track kit installation instructions.
Track System Serial Numbers
Record your PROSPECTOR PRO track system serial numbers below.
Track System Serial Number: ________________________________________
Rubber Track Serial Number: ________________________________________
Track System
Serial Number Rubber Track Serial Number
WARNING

SAFETY
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SAFETY
Safety/InformationLabels
Warninglabels have been placed on the track system for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your track system,
always read and follow the instructions of the labels on the track system.
Do not remove the warning labels from the track system. If an
informationalor graphic label becomes illegible or comes off, contact
your POLARIS dealer to purchase a replacement.
General Warning Label
Tensioner Bolt Warning Label
USER MANUAL - Every user must read this user manual.
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.
MOVING PARTS - Moving parts can crush and cut. Keep hands
and body clear of moving parts. Turn the engine off before
servicing track systems.
TECHNICAL MANUAL - Read and understand the technical
manual before servicing this machine. Follow the instructions
contained in the Maintenance Schedule section of the user
manual.
DO NOT loosen the tensioner assembly bolt
under any circumstance. DO NOT loosen this 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.

OPERATION
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OPERATION
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.
Serious injuries may result if hands, feet or clothing become entangled
in a moving track. Stay clear of all moving tracks.
Pre-Use Inspection
WARNING! Operating the vehicle with a damaged track increases the
possibility of track failure, which could cause loss of control resulting in
serious injury or death. Always inspect the track for damage before
using the vehicle.
Survival Preparation/RemoteTerrain Operation
When traveling off trails in remote terrain, always carry survival
equipment appropriate to the conditions you may encounter. Such
equipment may include, but is not limited to: a shovel, a first aid kit, extra
clothing,a sleepingbag, a flashlight,food and water, a signaling mirror,a
means of building a fire and a two-way radio or cellular telephone. If
possible, carry essential spare parts for emergency repairs.
1. Inspect the track and all
track system components
for wear or damage.
Never operate with a
damaged track.
2. Inspect wheels and
moving parts for
excessive mud, snow, ice
and debris.Make sure the
system can operate freely
and that components are
not bound by these
elements.
3. Clear away any snow, mud or debris that may hinder or block
proper operation of the vehicle’s cooling and steering systems, air
intakes and exhaust outlets.
4. After the initial installation, and after every futurereinstallationof the
tracks, always adjust track angle of attack, system
alignment and
track tension after the first use of the vehicle. See pages 18-25.
WARNING

OPERATION
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Safe Operation Practices
1. Read and understandthis user manualand 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. Never exceed the maximum weight capacity of the vehicle. When
determining the weight you are adding to the vehicle, include the
weight of the operator, passenger, accessories, loads in the rack or
box and the load on the trailer tongue. You must also include the
added weight due to removing wheels and adding track
systems. The
combined weight of these items mustnot exceed the maximum weight
capacity.
4. When cargo load is 220 lbs. (100 kg) or more, always reduce speed
significantly and operate with extra caution on rough terrain.
5. Operate the vehicle in 4X4 mode when operating with tracks. This will
significantly reduce the possibility of derailing.
6. The vehicle will handle differentlywhen a track system is installed.
Select an open area that allows room to familiarize yourself with
vehicle operation and handling. Drive slowly at first. On level
surfaces, practice starting, stopping, turning, maneuvering, using the
throttle and brakes and drivingin reverse. Learnhow the vehicle
handles when making both left and right turns at a slow speed.
7. Track systems are designed to reduce ground pressure and increase
vehicle traction.For the best traction, drive at slow speeds. Traction is
reduced at faster speeds.
8. 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.

OPERATION
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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.
11. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
12. When driving in deep snow, avoid spinning the tracks, which could
cause the vehicle to become stuck. When under power, tracks will
continue to turn in deep snow even if the vehicle fails to move.
13. When driving in snow, allow for a greater braking distance.
Periodically apply the brakes while driving to prevent ice buildup on
brake components.
14. Never operate on a frozen body of water.

OPERATION
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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.
If making a steep descent is unavoidable, drive straight downhill. Avoid
making turns during steep descents.
Towing a Stuck Vehicle
If your track-equippedvehicle must be towed from deep snow, always
tow in the opposite direction of vehicle travel. Do not attempt to tow the
vehicle in the same direction it had been travelingwhen it became stuck
in the deep snow.