Dennis Kirk 70207 User manual

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InstructionDisclaimer
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Dennis Kirk provides instructions to help our customers better understand how to install the
products we sell. The instructions are exact copies of what the manufacturer includes with the
product being sold.
That means the quality and accuracy of the instructions is solely dependent on what the
manufacturer produces. We do our best to make the text legible and the pictures viewable.
However, the end result depends largely on the quality of instructions the manufacturer
provides.
Therefore, you will find that some instructions are not of the highest quality. Sometimes text is
hard to read and pictures are not easy to see. At times you will find the overall look of the
instructions to be less than professional. However, we feel it is better to provide what we have
rather than provide nothing at all.
To the best of our knowledge the instructions and application information contained in the
instructions is accurate. However, Dennis Kirk assumes no liability related to any errors that
may be contained in the copy of the manufacturer’s instructions we provide. Buyers are solely
responsible to insure that product use is consistent with their application.
If you have any questions please contact us at [email protected] or
800-969-7501 so we can further assist you regarding additional product information or any other
business related questions.
Thank you for doing business with Dennis Kirk.

WARN INDUSTRIES PAGE1 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
Always 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.
Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips.
Flying chips can cause eye injury.
Always use extreme caution when cutting and trimming during fitting.
Always remove jewelry and wear eye protection.
Never lean over battery while making connections.
Never route electrical cables:
Across any sharp edges.
Through or near moving parts.
Near parts that become hot.
Always insulate and protect all exposed wiring and electrical terminals.
Always install terminal boots as directed in installation instructions.
Always use appropriate and adequate care in lifting components into place.
Always insure components will remain secure during installation and operation.
Always tighten all nuts and bolts securely, per the installation and operation.
Always perform regular inspections and maintenance on the winch, winch mount and related hardware.
Never operate this WARN product with damaged or missing parts.
WARNING
INSTALLATION INSTRUCTIONS
Winch Mounting Kit
Winch Mount Kit: 70207
Application: Kawasaki Brute Force
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:
WARNING signals a hazard that could cause serious injury or death, if you do not follow
recommendations. 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 PAGE2 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
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.
Read installation and operating instructions thoroughly.
Table of Contents
I. Parts List .......................................................3
II. Tools Required ..............................................3
III. Installation .....................................................4
IV. Specific Wiring Instructions ...........................6
V. Maintenance/Care .......................................10
Caution
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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.

WARN INDUSTRIES PAGE3 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. Tools Required
• Ratchet
• Sockets: 10mm, 1/2”
• Wrenches: 1/2”
I. Parts List
Ref Description Qty
A1 Winch Mounting Plate 1
B1 5/16-18 x 1 1/8” x 1 3/4” U-bolt 4
B2 5/16-18 x 1 1/2” x 2 3/16” U-bolt 2
B3 5/16” Flat Washer 8
B4 5/16-18 Lock Nut 8
1/4-20 x 1” x 1 1/2” U-bolt 2
1/4” Flat Washer 4
1/4-20 Lock Nut 4
B1B1
B2 (B1 for 2008 and later model
years)
B3
B3
B3
B3
B4
B3
B4
B4
A1
B4

WARN INDUSTRIES PAGE4 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
III. INSTALLATION
1. Loosen the front bottom skid plate by
removing the front two 6mm bolts, Figure 1.
Keep the 6mm bolts for reinstallation of the
skid plate. Skid plate will not be removed from
vehicle, only will be rotated down. This will
allow room for winch plate installation.
2. Place winch mounting plate (A1) sideways in
between the front tube guards and vehicle
frame, Figure 2.
3. Rotate winch mounting plate (A1), Figure 3. Tilt
winch mount forward by raising rear face such
that the front right corner clears the front tube
guard, Figure 3.
Figure 1 Loosen Front Skid Plate
Figure 2 Install Winch Mounting Plate
Figure 3 Rear Support Mount Bracket
Remove Skid
Plate Bolts
A1
Rear Face
Front Right Corner
Front Tube Guards
A1

WARN INDUSTRIES PAGE5 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
4. Rotate the mounting plate (A1) into location,
Figure 4. Center the plate between the two front
tube guards.
5. Attach the mounting plate (A1) by sliding the
supplied 5/16” U-bolts (B1) and (B2) around the
tubes and through the plate, Figure 5. Fasten
the U-bolts with the supplied washers (B3) and
nuts (B4), ensuring that the plate sits flush
against the front and rear contact surfaces.
Tighten all 5/16” fasteners to the recommended
torque value of 12 N-m (9 ft-lbs).
Note: For 2008 and later model years B2 u-
bolt will be replaced with an additional
quantity (2) of B1 u-bolt; (Frame tube size is
smaller on 2008 and later model years and
smaller u-bolt allows for a more secure fit to
frame).
6. Install winch from the left side of the vehicle, as
sitting on the vehicle, Figure 6. Fasten winch
with hardware supplied with the winch. Mount
the winch so that the motor faces the right side
of the vehicle. Tighten the bolts to a
recommended torque of 17 N-m (12 ft-lb).
Also attach roller fairlead to the winch mounting
plate, Figure 6, using two hardware provided in
the winch kit. See instructions included in winch
kit for recommended torque.
7. Switch the winch clutch to freespool. Manually
feed the winch cable through the roller fairlead.
Attach the clevis hook to the end cable loop,
Figure 7. Reinstall front skid plate with original
hardware from step 1 and securely tighten.
8. Complete the winch installation as described in
the winch installation and specification guide that
came with the winch.
Winch and winch mount installation is now
complete and should look like Figure 7.
Proceed to section IV, entitled “Specific
KVF750 Wiring Instructions”.
Figure 4 Place Winch Mounting Plate into Location
Figure 6 Install Winch and Roller Fairlead
Figure 5 Fasten Winch Mounting Plate
Front Tube Guards
A1
Rear Contact Surface
B1
B2
Install Winch From Left
Roller Fairlead
Front Contact Surface
B3 & B4

WARN INDUSTRIES PAGE6 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
FAILURE TO SECURELY TIGHTEN ALL BOLTS
ON THE WINCH PLATE, WINCH, AND FAIRLEAD
CAN RESULT IN PRODUCT FAILURE WHICH
MAY RESULT IN VEHICLE DAMAGE AND OP-
ERATOR INJURY OR DEATH. DOUBLE CHECK
THAT ALL BOLTS ARE SECURELY TIGHTENED
PRIOR TO USE.
WARNING
Figure 7 Complete Winch Installation
Clevis Hook
Front Skid Plate
IV. Specific KVF750 Wiring Instructions
IT SHOULD BE NOTED THAT THE FOLLOWING
INSTRUCTIONS ARE UNIT SPECIFIC. THE
FOLLOWING INSTRUCTIONS SHOULD BE
REFERRED TO AS REFERENCE INSTRUCTIONS
TO ASSIST WIRING THE WINCH FROM THE
INSTALLATION AND SPECIFICATION GUIDE
SUPPLIED IN THE WINCH KIT.
Notice WARNING
AVOID ALL MOVING AND POTENTIALLY HOT
COMPONENTS OF ATV WHEN ROUTING
ELECTRICAL CABLES. AVOID AREAS WHERE
THE WIRING COULD BE PINCHED WHEN
COMPONENTS ARE REINSTALLED. FAILURE
TO DO SO CAN RESULT IN PRODUCT
FAILURE WHICH CAN LEAD TO VEHICLE
DAMAGE AND OPERATOR INJURY OR DEATH.
1. Wiring Contactor Installation
a. Remove seat shown in Figure 11.
b. Remove air filter cover shown in Figure 12.
c. Remove the battery cover shown in Figure 13.
d. Remove cover under handlebars shown in
Figure 14.
Figure 11

WARN INDUSTRIES PAGE7 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 13
Battery Cover
Figure 12
e. Remove side pocket panel shown in Figure 15.
f. Remove side panel shown in Figure 16.
g. Secure contactor with supplied U-bolts, washer
and nuts, supplied in winch mounting kit, see
Figure 17.
Note: Do not over tighten U-bolts, this may
damage the contactor.
h. Route the red and black battery electrical cables
in-between the air box and then around the
battery, shown in Figure 18 and 19.
i. Route the blue and yellow cables along frame as
shown in Figure 17.
Note: For 2008 and later model years a
conduit has been factory supplied on the
ATV running from the winch mount area to
the contact mount area next to air box. Blue
and yellow cables can be routed through this
conduit from winch to contactor. Conduit
may be trimmed as required to ease
installation.
j. Use cable ties, supplied in the winch kit, to
secure all electrical cables to the ATV frame, as
needed. Avoid all moving and potentially hot
components of the ATV when routing the
electrical cables. Avoid areas where the wiring
could be pinched when components are
reinstalled (such as the seat).
k. Attach the red wire to the positive red contactor
post and battery positive terminal. Attach the
black wire to the black contactor post and
battery negative terminal. Reposition the
protective boot over the positive battery terminal.
l. Re-assemble all panels and covers.
Figure 14
Remove Cover
Remove Air Filter Cover

WARN INDUSTRIES PAGE8 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 15
Figure 16
Figure 17
Side pocket panel
Side panel
Blue & Yellow Cables
m. Reinstall the battery cover and securely tighten
fasteners.
n. Refer to the winch installation and specification
guide for full and complete details on wiring
installation.
Contactor
Black & Red Cables

WARN INDUSTRIES PAGE9 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 18
Figure 19
Air Filter
Battery
Red Cable Black Cable

WARN INDUSTRIES PAGE10 70208A2
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
READ THE VEHICLE’S OPERATOR MANUAL,
WINCH OPERATOR MANUAL, AND ALL WARN-
ING LABELS PRIOR TO OPERATION OF ATV
AND WINCH.
WARNING
WARNING
AVOID ALL MOVING AND POTENTIALLY HOT
COMPONENTS OF ATV WHEN ROUTING
ELECTRICAL CABLES. AVOID AREAS WHERE
THE WIRING COULD BE PINCHED WHEN
COMPONENTS ARE REINSTALLED. FAILURE
TO DO SO CAN RESULT IN PRODUCT
FAILURE WHICH CAN LEAD TO VEHICLE
DAMAGE AND OPERATOR INJURY OR DEATH.
V. MAINTENANCE/CARE
1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all
hardware that appears rusted or deformed.
2. Inspect all nuts and bolts on the winch, winch mount,, and related hardware prior to each use. Tighten
all nuts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced.
3. Check all cables prior to use. Replace cables that look worn or frayed.
4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.
WARNING
PERFORM REGULAR INSPECTIONS ON THE WINCH, WINCH MOUNT, AND RELATED HARD-
WARE. NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE TO
FOLLOW THIS WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.