User Manual 1099-01-1005 - VERSION B TATOU® 4S ATV Track System Original notice Other languages translation available at www.camoplast.
Camoplast Inc. 1701, 3rd Avenue Grand-Mère, (Québec) J1X 0E6 CANADA E-mail : atvtracksystems@camoplast.com Website : www.camoplast.com © 2008 IMPORTANT Please read carefully each part of this document as well as model specific Installation Guidelines prior to assembling, installing and using the track system. ® and TM are trademarks of Camoplast Inc. All rights reserved. ©2010 Camoplast Inc. Printed in Canada.
TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 USING THE ATV WITH TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HINTS AND TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION INTRODUCTION Thank you for choosing Tatou® 4S, a Camoplast ATV Track System, (hereinafter referred to as the "System"). You have made the right choice. This system will provide you with all the traction, performance and durability you require for recreational or work purposes and allows for year-round operation. This track system for quads (hereinafter referred to as the "ATVs") provides exceptional floatation with very low ground pressure.
USING THE ATV WITH TRACKS Always follow the ATV manufacturer's safety rules and regulations regarding, for exemple passengers transportation, maximum loads, ect. It is the driver’s responsibility to follow the recommended schedules maintenance further described in this manual.
HINTS AND TIPS HINTS AND TIPS Before leaving for an excursion, make sure you have the following within arms reach : 12 mm, 14mm, 16 mm, 17 mm, 19mm and 30 mm wrenches, one axe, one shovel, one tow cable, a lifting jack and one adjustable wrench. Generally, the slower you go, the better the traction will be. For riding or excursions in unknown, or remote terrain, make sure you have a cellular phone or satellite phone, a first aid kit and spare parts in your possession.
SAFETY SAFETY This guide uses the following symbols to emphasize particular information : WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in damage to vehicle components. NOTE: Indicates supplementary information.
USER NOTICE AND DISCLAIMER The System consists of many moving parts, including transmission wheels. If an object lodges itself or becomes jammed into the System and blocks the track, it is mandatory to stop the engine and the vehicle and apply the security brake before removing object said. By avoiding to do so, the user exposes himself to sudden movement of the ATV or to breakage of a part or component coming from the System, which could cause severe injuries.
USER NOTICE AND DISCLAIMER capacities allow. Excessive speed remains one of the main causes of severe accidents on ATVs. Camoplast is proud to offer ATV conversion kits within its wide range of products. ATV Track Systems are not only reliable, but safe. However, there are risks inherent to driving an ATV equipped with the System.
DANGEROUS SITUATIONS DANGEROUS SITUATIONS When using a vehicle equipped with track systems, it is important to respect the following safety recommendations. As driving a vehicle equipped with track systems is different from driving a vehicle with wheels, it is strongly recommended that the safety guidelines provided below are followed to prevent any accidents and serous malfunctions that could affect the occupants, the vehicle or to the track systems for occurring.
DANGEROUS SITUATIONS Steep descents WARNING It is not advisable to change direction during steep descents. This can lead to a serious malfunction of the ATV’s steering system and track systems. During a steep descent, it is advisable to keep the handlebar in a forward direction and to begin turning when the ATV is on flat ground, thus to avoid subjecting the components of the vehicle and the system to any high stress.
DANGEROUS SITUATIONS Descending and being stuck in reverse WARNING If the 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. It is advisable to remove the snow from the top of the rear track systems and to compact it using your feet, behind the systems to dislodge the track.
DANGEROUS SITUATIONS Towing a vehicle out of the snow WARNING If your vehicle must be towed out of the snow, never tow it in the direction in which it sank. Tow the vehicle in the direction of the trail it left as it became stuck.
DANGEROUS SITUATIONS Loading a vehicle into and unloading it from a truck WARNING When a vehicle is being loaded into or unloaded from a truck box, it is extremely important to ensure that the front tracks do not grip the locking gudgeons of the truck’s tailgate as this could cause them to tear.
DANGEROUS SITUATIONS Driving over an obstacle Driving over a steep ridge WARNING It is not advisable to attempt to drive over an obstacle, such a tree trunk, a big rock or a steep ridge that could lodge itself between the front and the rear track systems and immobilize the vehicle. The best option remains to bypass this type of obstacle.
INSTALLATION, REMOVAL AND RE-INSTALLATION INSTALLATION, REMOVAL AND RE-INSTALLATION WARNING Never place body parts under the vehicle unless it is securely placed on appropriate stands. Severe injuries could occur if the vehicle collapses or moves. Do not use a lifting device as a secure stand. Always follow good shop practices. The place where you will be working must be security, clean, bright and well ventilated. If you are to use a floor jack, never use it as a stand. Always use appropriate stands.
INSTALLATION, REMOVAL AND RE-INSTALLATION WARNING To avoid any injury to your hands during the manipulation of the systems, we recommend you to manipulate the systems at places indicated in following figure. Installation Execute all tasks described in Installation Guidelines of the vehicle model. Then, proceed to adjust the angle of attack, alignment and track tension as described in this manual. Test drive and re-adjust as required.
INSTALLATION, REMOVAL AND RE-INSTALLATION At the front: • Remove the anti-rotation bracket cover but keep the anchor bracket attached to the anti-rotation device on the track system. Figure 1 Leave anchor bracket attached to the stabilizing rod. • Remove track systems. • Re-install wheels. At the rear on an independent suspension: • Same procedure as the front. At the rear on a rigid axle suspension: • Disconnect the anti-rotation bar from the skid plate under the vehicle.
INSTALLATION, REMOVAL AND RE-INSTALLATION Re-installation Always clean wheel hubs on the ATV before installing wheels or track systems. Figure 2 Clean wheel hubs. • Re-install track systems at the rear and secure stabilizing rod to anchor bracket for rigid axle. • Re-install track systems at the front. • Tighten the fasteners in an alternate crosswise pattern to the torque recommended by the manufacturer. • Verify track tension. Adjust if required. • Verify angle of attack. Adjust if required.
ADJUSTMENTS ADJUSTMENTS Angle of attack for front tracks systems To obtain the correct angle of attack on front tracks systems, perform the following : • Loosen the nut (1) compressing the spring of the stabilizing rod (refer to Figure 3). Figure 3 • Set steering handles straight ahead. • Temporarily apply pressure to the front of the track to make sure that it stays flat on the ground. • Install a flat bar on rear wheels of the track systems and measure the height as shown on Figure 4.
ADJUSTMENTS Figure 4 • Set the nut (2) shown on Figure 5 until the flat bar reaches 254 ± 6 mm above the ground. For right hand side, rotating the wrench towards A makes the system rotate towards C while rotating the wrench towards B makes the system rotate towards D (reverse for left hand side).
ADJUSTMENTS • Turn the nut (1) until it comes in contact with the spring, then compress the spring by turning this nut 1.5 turns (refer to Figure 6). Figure 6 NOTE: In certain rare cases, where the adjustment of the nut (article 1 on Figure 6) compressing the spring, is close to the end of the threaded rod, lengthen the assembly by loosening the locknut (article 3 on Figure 7) and unscrewing the rod end so that a maximum 19 mm of its threads are visible.
ADJUSTMENTS Figure 7 Basic Tuning (front track systems): • An adjustment of more than 254 mm measured with the flat bar, gives easier steering with wobbling effect at high speed. • An adjustment of less than 254 mm measured with the flat bar, gives harder steering and more stability at high speed. • More spring recommended. preload (compression) : not • Less spring preload (compression): gives better articulation when riding on deep and powder snow. It will not affect the steering effort.
ADJUSTMENTS Angle of attack for rear track systems To obtain the correct angle of attack on rear tracks systems, perform the following : Vehicles with rigid axle or trailing arm suspension • Loosen the nut (1) compressing the spring of the stabilizing rod (see Figure 8). • Set the nut (2) to obtain a distance of 10 mm as shown. • Turn the nut (1) until it comes in contact with the spring, then compress the spring by turning this nut 1.5 turns.
ADJUSTMENTS Vehicles with independent suspension • Loosen the nut (1) compressing the spring of the stabilizing rod (refer to Figure 9). • Turn the nut (2) until it comes in contact with both rubber damper and bracket (3). Then, compress the rubber damper by turning the nut (2) one turn. • Turn the nut (1) until it comes in contact with the spring. Then compress the spring by turning this nut 1.5 turns.
ADJUSTMENTS NOTE: In some rare cases where the adjustment of the nut (1) compressing the spring is near the end of the threaded rod, extend the rod by unlocking the jam nut (item 3 on Figure 10) and unscrew the rod to obtain 19 mm max. of visible threads. Re-tighten the jam nut. Figure 10 Basic tuning (rear track systems): • More gap at the rubber bushing gives better obstacle climb and flotation capacity on powder snow while moving forward.
ADJUSTMENTS Alignment The parallelism must be adjusted with the ATV on the ground, driving forward on about 3 m and measuring toe in distance.(refer to Figure 11). NOTE: Every time the measurement has to be verified, drive in reverse, then, drive forward again on about 3 m. B - A = 0 ± 3 mm Figure 11 To perform adjustments on the ATV, first unlock the nut (1) of each tie rod end on the ATV. Then screw or unscrew the rod link (2) equally on both sides of the vehicle.
ADJUSTMENTS Rubber track tension Adjust the tension the rubber track by turning the adjusting nuts of the track tensioner. Adjust track tension. A force of 11 kg positioned as shown should produce a deflection of 19 mm (refer to Figure 14). Figure 13 The tool 1, used on the figure 14, can be bought in the majority of car parts stores. The brand is Gates Corporation and the part number is 7401-0076.
ADJUSTMENTS The following table indicates the force (1) applied and the deflection (2) which must occur according to the conditions of use. Season Summer Winter (snow) Track Front Rear Front Rear Force 15 kg 15 kg 11 kg 11 kg Deflection 19 mm 19 mm 19 mm 19 mm Figure 14 Basic tuning • A higher rubber track tension reduces the risk of “detracking” and reduces drive “ratcheting” (for severe use only).
INSTALLATION OF A RUBBER TRACK INSTALLATION OF A RUBBER TRACK If possible, position the vehicle on a flat and level surface (or on a suitable lift device). Turn off the engine. Proceed as follows : • Set rubber track tension to the minimum (refer to Figure 15). Figure 15 • Remove the two 201-mm wheels opposite to the track tensioner side (refer to Figure 16). • If working on rear track systems, remove the two 133mm wheels next to the 201-mm wheel.
INSTALLATION OF A RUBBER TRACK Figure 16 • Install the rubber track (refer to Figure 17). NOTE: Compare with the other rubber tracks to find the correct orientation. Figure 17 • Re-install 201-mm wheels. • If working on rear track systems, re-install the 133-mm wheels (refer to Figure 18).
INSTALLATION OF A RUBBER TRACK NOTE: If possible, modify a screwdriver blade as shown on the picture to facilitate the task of inserting the wheels on their shafts. Otherwise, use a No. 2 Phillips screwdriver. Figure 18 • Adjust track tension. Refer to ‘Rubber track tension” on page 25.
BREAK-IN PERIOD BREAK-IN PERIOD A break-in period is necessary in order to allow the components of the system to match themselves to each others. During the break-in period (4 hours or 80 kilometers), follow these recommendations : • Avoid running under dry and clean conditions. (For example: asphalts, hay or straw field, etc). • Start sharp turns at very low speed: (15 km/h maximum at speedometer).
REPLACEMENT OF A WHEEL WITH EXTRACTOR REPLACEMENT OF A WHEEL WITH EXTRACTOR WARNING Do not use air tools to remove the wheels. Use Tatou extractor # 2000-00-1050 (article 1, Figure 19), and the following procedure to make the replacement: Figure 19 • Remove the rubber cap of the wheel. If the wheel is retaining by a bolt, unscrew it and remove the wheel. • If there is no bolt, use the alignment sleeve (article 2, Figure 19) to locate the extractor.
REPLACEMENT OF A WHEEL WITH EXTRACTOR • Place the extractor under the wheel as shown on Figure 20 • Then screw the threaded rod to remove the wheel. Figure 20 • Insert the new wheel on the shaft until it reaches the shoulder.
MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE 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. For optimum performance and maximum durability, please refer to the following maintenance grid : NOTE: Phillips screwdriver.
TORQUE TABLE TORQUE TABLE Bolt N-m M8 - 8.8 M10 - 8.8 M10 - 10.9 M12 - 10.9 25 50 70 125 STORAGE The best way to store the System is to lay down each frame on its side, away from direct sunlight.
WEAR WEAR Wheel Verify the wear of the wheels especially on the interior guidance strip (figure 21). If the internal plastic structure is visible, the rubber coating is worn and the wheel must be replaced (as illustrated figure 22-2), or when the wear of the wheel’s rolling band reaches a thickness of 17 mm, figure 23 (20.5 mm when new). A wheel that is excessively worn will not offer enough support for the track's guidance.
WEAR Figure 22 Figure 23 36
WEAR Track guide Verify the wear of the track guide by measuring the width of the guide. If dimensions of the guide illustrated in figure 24 are lower than 5 mm, at any place, replace the part. If the guidance strip is worn so that the concave shape is no longer visible, replace the part. An overly worn track guide could prematurely wear the other components of guidance of the system.
WEAR Figure 25 Anti-rotation Verify the wear of anti-rotation system, mainly at the ball joint (figure 26) to make sure that it is not seized or extremely loose. Ball joint damage could harm the performance of the track system.
WARRANTY WARRANTY Camoplast guarantees that the new, unused Tatou® 4S System (System) installed by an authorized dealer or distributor is free from any defects in materials and workmanship during the period and in conditions described below. When operating a new Tatou® 4S System, the user agrees that the present form is applicable and exclusive, that they have been signified and that they have been accepted by him/her at the time of purchase.
WARRANTY 5) Damage resulting in abusive use, abnormal use, negligence or even a use which does not comply with recommendations of the manual, excess weight or loading, including excessive number of passengers. 6) Labour costs, parts and materials related any and all maintenance costs.
TROUBLESHOOTING TROUBLESHOOTING TROUBLE SHOOTING Problem Potential cause Correction to do Abnormal vibration Presence of debris in the system. Remove any debris which could prevent the proper operation of the system Severe and localized wear of a wheel ( Replace the part flat spot) Sprocket or wheel frozen Remove the ice/snow build up.
SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION The following pictures show the location of the serial numbers on the track system frame and rubber track.
TECHNICAL SUPPORT TECHNICAL SUPPORT If your dealer or distributor is unable to solve a problem related with the System, you may contact the Camoplast support team from Monday to Friday. Camoplast Inc. 1701, 3rd Avenue Grand-Mère, (Québec) J1X 0E6 CANADA E-maill : atvtracksystems@camoplast.com Website : www.camoplast.
’’CE’’ DECLARATION OF CONFORMITY ’’CE’’ DECLARATION OF CONFORMITY CE DECLARATION OF CONFORMITY WE: MANUFACTURER : CAMOPLAST INC. ADRESS : 1701, 3 IÈME AVENUE Grand-Mère (Québec) Canada G9T 2W6 PHONE : (819) 533-0008 FAX : (819) 533-5532 WEB SITE : www.camoplast.
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Item # # Pièce/ Part Description QTY TATOU 4S - MY2011 FRONT LEFT & RIGHT 1 2 3 4 5 6 7 8 9-A 9-B 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41-A 41-B 42 43 44 45 46 47 1001-00-7102 1008-77-0010 1008-77-0020 1008-77-0040 1009-00-7115 1009-00-7116 1009-00-7117 1009-00-7118 1010-00-722X 1011-00-722X 1014-00-722X 1015-00-7010 1015-00-7103 1016-00-0133 1016-00-0201 1017-00-0001 1017-00-0005 1017-00-0010 1017-00-0110 1017-00-7011 1019-05-0010 1019-77-0011 10
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Item # # Pièce/ Part Description QTY TATOU 4S - MY2011 REAR LEFT & RIGHT 1 2 3 4 5 6 7 8-A 8-B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38-A 38-B 39 40 41 42 43 44 1008-77-0010 1008-77-0020 1008-77-0040 1009-00-7115 1009-00-7116 1009-00-7117 1009-00-7118 1012-00-722X 1013-00-722X 1014-00-732X 1016-00-0133 1016-00-0201 1017-00-0001 1017-00-0010 1017-00-0110 1017-00-7011 1019-05-0010 1019-77-0011 1019-77-0031 1033-08-0080 1033-10-2026 1033-10-2030 1033-12-7030
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Item # # Pièce/ Part Description TATOU 4S - MY2011 INDEPENDENT SUSPENSION (IS) OPTION QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1000-00-7002 1001-00-7102 1015-00-7005 1015-00-7026 1015-05-7005 1033-10-1060 1033-10-2025 1033-10-2045 1047-00-7010 1050-00-0013 1060-00-0004 1071-20-0001 1073-12-3002 1074-10-0001 1080-00-0002 1093-00-7007 THREADED ROD, STABILIZING ROD STABILIZING ROD ASS'Y, 200 LBS/IN BRACKET ANTI-ROTATION (IS) BACK PLATE SPACER 5/8", ANTI-ROTATION BRACKET HEX SCR, ISO 4014 (DIN 931), 10.
