Warn 80545 Manuale utente

WARN INDUSTRIES PAGE 1 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

INSTALLATION INSTRUCTIONS

PLOW MOUNTING KIT

Part Number: 80545

Application: Polaris Sportsman XP

WARNING

AlwAlw

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Alwaa

aysys

ysys

ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.

AlwAlw

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aysys

ysys

ys use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other

objects are not punctured or damaged when/if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of

material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in

vehicle damage, electrical shock, fire or personal injury.

AlwAlw

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aysys

ysys

ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye

injury.

AlwAlw

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Alwaa

aysys

ysys

ys use extreme caution when cutting and trimming during fitting.

AlwAlw

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aysys

ysys

ys remove jewelry and wear eye protection.

NeNe

NeNe

Nevv

verer

erer

er lean over battery while making connections.

NeNe

NeNe

Nevv

ver rer r

er rer r

er routout

outout

oute electrical cables:e electrical cables:

e electrical cables:e electrical cables:

e electrical cables:

oAcross any sharp edges.

oThrough or near moving parts.

oNear parts that become hot.

AlwAlw

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aysys

ysys

ys insulate and protect all exposed wiring and electrical terminals.

AlwAlw

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aysys

ysys

ys install terminal boots as directed in installation instructions.

AlwAlw

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aysys

ysys

ys use appropriate and adequate care in lifting components into place.

AlwAlw

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aysys

ysys

ys insure components will remain secure during installation and operation.

Alw

Alw

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aysys

ysys

ys tighten all nuts and bolts securely, per the installation instructions.

AlwAlw

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aysys

ysys

ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.

AlwAlw

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aysys

ysys

ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.

NeNe

NeNe

Nevv

verer

erer

er operate the vehicle on slopes greater than 10 degrees with the plow installed.

NeNe

NeNe

Nevv

verer

erer

er stand or ride on the plow.

AlwAlw

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Alwaa

aysys

ysys

ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.

AlwAlw

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aysys

ysys

ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

AlwAlw

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aysys

ysys

ys replace all worn or damaged parts before operating.

NeNe

NeNe

Nevv

verer

erer

er operate this WARN product with damaged or missing parts.

AlwAlw

AlwAlw

Alwaa

aysys

ysys

ys drive slowly over bumpy and rough terrain. Driving at speeds that cause the plow to bounce while in the up position can

cause the winch to back-drive, causing the plow to work its way down. This may result in the plow impacting a stationary object

and cause damage to the vehicle and operator injury or death.

AlwAlw

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aysys

ysys

ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.

AlwAlw

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aysys

ysys

ys be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious

damage to the ATV if the plow is raised too high. The plow blade will drop suddenly if the j-bolt breaks, so always be sure there

are no bystanders when you raise and lower the plow.

Ne

NeNe

Nevv

verer

erer

er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

AlwAlw

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aysys

ysys

ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.

INJURY HAZARD

Failure to observe these instructions could lead to severe injury or death.

Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we

have provided installation and operating instructions and other information on labels and in this guide. This

information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all

potential hazards associated with this product, you must use your own good judgment.

CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR

EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND

OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.

This guide identifies potential hazards and has important safety messages that help you and others avoid personal

injury or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words

mean:

WARNINGsignals a hazard that could cause serious injury or death, if you do not follow recommenda-

tions. CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow

recommendations.

This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general

information worthy of special attention.

WARN INDUSTRIES PAGE 2 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

I. TABLE OF CONTENTS

Tools Required page 2

Parts List page 3

Installation page 4-6

Polaris Winch Mount page 4

WARN Winch Mount page 5-7

Maintenance/Care page 7

CAUTION

Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury.

Always take time to fully read and understand the installation and Operations Guide included with this product.

Never operate this product if you are under 16 years of age.

Never operate this product when under the influence of drugs, alcohol or medications.

Read installation and operating instructions thoroughly.

NOTICE

Equipment Damage

Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific details on how

to wire this WARN product to your vehicle.

Never overtighten the j-bolt to the bracket. Doing so will pinch the winch cable against the bracket, damaging the cable.

Always put the end of the actuator cable through the slot in the Termination Bracket. Terminating the cable through any other hole in the

bracket will cause the bracket to not function properly and will drastically reduce the life of the actuator cable.

Read installation and operating instructions thoroughly.

II. TOOLS REQUIRED

- 3/8" Rachet with 3-1/2" extension

- Sockets: 10mm, 13mm, 16mm

- Wrenches: 13mm, 16mm, 17mm

WARN INDUSTRIES PAGE 3 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

IMPORTANT: This kit requires either a Polaris or WARN winch mount to be installed. It cannot be mounted if a

winch mount has not been installed on the vehicle

III. PARTS LIST

Ref Description Qty

1 Plow Mount 1

2 M10-1.50 x 25mm Hex Bolts 4

3 Flat Washer 3/8" 2

4 Capscrew M8-1.25 x 20mm 2

5 Plow Retaining Pin 2

6 Plow Tab RH 1

7 Plow Tab LH 1

8 WARN Winch Mount Adapter Brkt. 1

9 Lock Washer M10 2

10 Nut M10x1.50

Use Holes (A) if mounted with a Polaris Brand Winch Mount.

Use Holes (B) if mounted with a WARN Brand Winch Mount.

WARN INDUSTRIES PAGE 4 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

Figure 1

IV. INSTALLATION (Polaris Winch Mount)

Figure 2

Note: The Polaris winch mount (Figure 1) already

has mounting holes underneath the fairlead rollers

and does not need the adapter bracket.

1. If using the Polaris winch mount, loosen the bolts

securing the mount to the vehicle (Figure 2) so the

winch mount is loosely attached. Remove the lower

skid pan bolts. These will not be used in this kit.

2. Place the plow mount under the vehicle such that the

tabs fit around the frame cross bar that the lower skid

pan bolts thread into. Secure with two M8x20mm

capscrews supplied and a 13mm socket (Figure 3).

Do not tighten these.

Note: It may be necessary to line one side up first,

applying inward pressure on the skid plate

mounting tabs to fit in between the plow mount tabs

and around the cross tubing.

3. Secure the plow mount to the winch mount. Use a

16mm socket with two M10x25mm bolts with 3/16"

flat washers (Figure 4). Do not tighten all the way.

Note: It may be necessary to rotate the winch

mount upward for the mounting holes to line up

with the plow mount holes. Make sure the lower

M8x20mm bolts are not tight, as it will make this

step difficult.

4. Tighten the two lower M8x20mm bolts to 20 N-m

(15 ft-lbs). Tighten the two plow mount to winch

mount M10x25mm bolts to 25 N-m (18.5 ft-lbs).

Tighten the four winch mount to frame bolts to 20 N-

m (15 ft-lbs).

5. Finally install the plow mounting tab to your Plow

Tube Assembly. Install these loosely on the plow

with the fasteners provided with the plow. Tighten

the fasteners after the plow is assembled and installed

in the mount according to the plow assembly

instructions.

Figure 3

Figure 4

WARN INDUSTRIES PAGE 5 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

Figure 5

Figure 6

IV. INSTALLATION (WARN Winch Mount)

Figure 7

1. Remove the front skid plate (Figure 5). Use a 13mm

socket to remove the four bolts securing the front

skid pan to the front bumper.

2. Remove the WARN winch mount. Use a 13mm

socket and a 13 mm wrench to loosen the four bolts/

nuts that secure the WARN winch mount to the

frame (Figure 6).

3. Remove the hook by pulling the cotter pin from the

clevis pin. Remove the fairlead from the WARN

winch mount. Use a 16mm socket with a 17mm

wrench to loosen the two M10x1.5x20mm bolts that

secure the fairlead to the winch mount. These bolts

will be replaced by longer fasteners provided in this

kit.

4. Place two M10x1.5x25mm bolts through the back of

the face of the WARN winch mount (Figure 7). Then

place the WARN winch mount adapter bracket on the

face of the winch mount feeding the bolts through the

mounting holes on the bracket. (Figure 8)

CAUTION

Once the winch mount is freed from the mount it

can fall from the vehicle. To prevent personal injury

and damage to the winch and its mount, remove the

top two bolts/nuts but only remove the nuts on the

bottom, leave the two bolts in the mounting holes.

Hold the winch mount with one hand, then remove

the last two bolts.

WARN INDUSTRIES PAGE 6 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

INSTALLATION CONT.

5. Place the fairlead over the adapter bracket, feeding

the bolts through the mounting holes on the fairlead.

Tighten two lock washers with two M10 nuts using a

16mm socket and 17mm wrench. Install the hook by

placing the clevis pin through the hook and securing

with cotter pin. (Figure 9)

6. Place the WARN winch mount back on the vehicle

mounting tabs and secure with bolts taken off in step

2. Do not tighten bolts all the way. The winch

mount needs to move slightly to install the plow

mount. (Figure 10)

7. Secure the front skid plate to the frame using only the

upper bolts, the lower bolts will not be used in this

kit. The front of the winch mount may have to be

rotated upward to get the skid plate holes to line up

with the frame.

8. Loosen the bolts securing the mount to the vehicle

(Figure 10) so the winch mount is loosely attached.

Remove the lower skid pan bolts. These will not be

used in this kit.

Figure 8

Figure 9

Figure 10

WARN INDUSTRIES PAGE 7 80546A1

WARN® and the WARN logo are trademarks of Warn Industries Inc.

INSTALLATION CONT.

V. MAINTENANCE/CARE

•Inspect all metal parts on the plow, plow mount, and related hardware. Replace all parts that appears rusted or

deformed prior to use.

•Inspect all nuts and bolts on the plow, plow mount, and related hardware prior to each use. Tighten all nuts and

bolts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced immediately.

•Check all cables prior to use. Replace cables that are worn or frayed.

•Check all moving and rotating parts. Remove debris that may inhibit the part from moving freely.

Figure 11

Figure 12

9. Place the plow mount under the vehicle such that the

tabs fit around the frame cross bar that the lower skid

pan bolts thread into. Secure with two M8x20mm

capscrews supplied and a 13mm socket (Figure 11).

Do not tighten these.

Note: It may be necessary to line one side up first,

applying inward pressure on the skid plate

mounting tabs to fit in between the plow mount tabs

and around the cross tubing.

10. Secure the plow mount to the winch mount. Use a

16mm socket with two M10x25mm bolts with 3/16"

flat washers (Figure 12). Do not tighten all the way.

Note: It may be necessary to rotate the winch

mount upward for the mounting holes to line up

with the plow mount holes. Make sure the lower

M8x20mm bolts are not tight, as it will make this

step difficult.

11. Tighten the two lower M8x20mm bolts to 20 N-m

(15 ft-lbs). Tighten the two plow mount to winch

mount M10x25mm bolts to 25 N-m (18.5 ft-lbs).

Tighten the four winch mount to frame bolts to 20 N-

m (15 ft-lbs).

12. Finally install the plow mounting tab to your Plow

Tube Assembly, see Figure 13. Install these loosely

on the plow with the fasteners provided with the

plow. Tighten the fasteners after the plow is

assembled and installed in the mount according to the

plow assembly instructions.

Figure 13

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