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
4
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
6
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
7
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
8
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
9
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
10
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.

OPERATION
11
Freeing a Vehicle Stuck While Backing
Downhill
If unsuccessful, stop the engine, place the transmission in forward gear
and engagethe park brake (if equipped).Remove any snow from thetop
of the rear track systems and pack down the snow lodged behind the
tracks, or use a shovel to clear away the snow.
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 downhillis unavoidable,
back slowly and back straight
downhill. If the vehicle becomes
stuck
in snow while backing
downhill, avoid towing or
operating the vehicle rearward, as
damage could occur. Operate in
forward gear
to free the vehicle.

OPERATION
12
Driving Over Obstacles
Obstacles are not always visible, especially in areas with deep snow or
mud. Avoid operatingin 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. Large obstacles may lodge between the
front and rear track systems and immobilize the vehicle.
Do not attempt to operate over obstacles more than 12 inches (30.5 cm)
in height. If unavoidable, always place a smaller log or rock near the
obstacle to serve as a ramp for the track.

OPERATION
13
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. The
tracksystemisdesignedtoslipinto
the drive system, preventing the
vehicle from being overloaded.
NOTE: Somes vehicles do not
have unlocked 4X4 mode
on the rear differential.
These vehicles should
avoid the situation
described above and take
wider turns instead.

OPERATION
14
Track Damage While Loading/Unloading
Tow Cable Use
If the track-equipped vehicle must be towed, always attach the tow cable
to the frame of the disabled vehicle. Never attach the tow cable to the
track system.
No Jumps and Stunts
A track maytear while loading
or unloadingthe vehicleinto 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. Use
caution when operating near
extendedbolts,barsorsimilar
appendages that could cause
tears to a moving track.
Attempting jumps and other
stunts increases the risk of an
accident or rollover. Never
attempt jumps or other stunts.
Avoid exhibition driving.

INSTALLATION/REMOVAL
15
INSTALLATION/REMOVAL
Safe Service Practices
Service and adjustmentsare important for proper vehicle operation. If
you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Always follow safe shop practices. The work space should be clean,
bright and wellventilated. Alwaysturn the engineoff beforeperforming
service.
WARNING! Severe injuries could occur if an elevated vehicle falls or moves.
Never place body parts under an elevated vehicle unless the vehicle is properly
immobilized on appropriate stands.
Do not use a floor jack or other lifting device as a stand. Always place
appropriatestands under an elevated vehicle and block any wheels that
remain in contact with the ground to prevent vehicle movement. Never
place body parts under an elevated vehicle unless the vehicleis properly
immobilized on appropriate stands.
Track System Installation
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.
2. 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. See pages 18-25.
To avoid injury to hands while
installing or removing track
systems, position hands on the
frame as shown.
WARNING! Serious injuries may
result if hands, feet or clothing
become entangled in a moving
track. Stay clear ofall moving
tracks. We recommend having
your dealer perform all track
system service and alignment
procedures.

INSTALLATION/REMOVAL
16
Track System Installation
Reinstallation
1. Using a suitable lifting
device, elevate the vehicle
andplace
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. Reinstall the rear track
systems, then reinstall the
front track systems.
5. Tighten fasteners in a criss-cross pattern to the manufacturer’s
recommended torque specification.Refer to your vehicle owner’s
manual or service manual.
6. 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. See pages 18-25.

INSTALLATION/REMOVAL
17
Track System Removal
1. Position the vehicle on a level surface.
2. Stop the engine.
3. Elevate the vehicle and place suitablestands under the frame. Make
sure the vehicle is immobilized.
result in severe damage to the vehicle when operating with wheels.
Skid plate and footrest reinforcement parts are the only components
that can remain on the vehicle when reinstalling wheels.
5. Remove the track system.
6. Clean the wheel hubs. Components may not seat properly on soiled
hubs.
7. Reinstall the wheels. Make sure all original components that were
removed for track installation are reinstalled properly for wheeled
operation. Refer to your vehicle owner’s manual or service manual.
Off-Vehicle Track System Storage
4. Remove the anti-rotation
bracket cover (1). Remove
the anchor bracket (2) from
the suspension arm, but
leave it attached to the anti-
rotation device on the track
system. The bracket should
remain attached to the sta-
bilizing rod (3).
NOTICE: Leaving the anchor
brackets attached to the
suspension arms can
After removing the track
systems from the vehicle, pour
5cc of oil under the wheel caps
to help prevent corrosion. Place
each system on its side and
store away from direct sunlight.

ADJUSTMENTS
18
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. Refer to the track kit installation instructions for
more information as needed. Perform steps 3-6 for both front track
systems.
1. Position the vehicle on a level surface.
2. Stop the engine.
3. Using the handlebars or steering wheel, make sure the tracks are in
the straight-ahead position.
4. Verify that the stabilizing arm
(1) is attached to the front
anchor bracket (2).
5. Verify that the spring
assembly bolt (3) is
tightened to specification.
Torque: 29.5 ft. lbs. (40 Nm)
6. Verify that stabilizing arm
components are installed in
the correct order. Refer to
the track kit installation
instructions for more information as needed.

ADJUSTMENTS
19
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. The
recommendeddistance from bar to ground is 12 1/8 inches (308 mm).
NOTE: Increasing the distance from bar to ground will result in easier steering,
but will produce a wobbling effect at high speeds. Decreasing the
distance from bar to ground will result in harder steering, but will
provide more stability at higher speeds.
8. If adjustment is necessary, loosen the jam nut (1).
9. Rotate the stabilizing arm (3) to adjust the length of the rod end (2).
Adjust until the distance measurement from the flat bar to the ground
is 12 1/8 inches (308 mm). Apply light downwardpressure to thefront
of the track while measuring the distance from the bar to the ground.
10. Tighten the jam nut (1) against the stabilizing arm.
11. Repeat the bar-to-ground measurement to verify the adjustment.

ADJUSTMENTS
20
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.
1. Verify that the stabilizing
arm (1) is attached to the
rear anchor bracket (2).
2. Verify that the spring
assembly bolt (3) is
tightened to specification.
Torque: 29.5 ft. lbs. (40 Nm)
3. Verify that stabilizing arm
components are installed in
the correct order. Refer
to the track kit installation
instructions for more
information as needed.
4. Loosen the anti-rotation
bracket bolts (1) and (2) to
allow the anti-rotation
retainer (3) to rotate on its
axis.