Warn Industries 80558 User manual

WARN INDUSTRIES PAGE 1 80565A1
©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 dam-
aged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, re or personal
injury.
Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying
chips can cause eye injury.
 Always use extreme caution when cutting and trimming during tting.
 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
Front Plow Mounting Kit
Front Plow Mount Kit: 80558
Application: 2007 + Suzuki King Quad 450-750
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 judg-
ment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT
DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUC-
TIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
This guide identies 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 recom-
mendations. 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 80565A1
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Notice
Equipment Damage
 Always refer to the Installation and Specication Guide, supplied in the winch kit, for all wiring schematics and specic 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 ....................................................4-6
IV. Maintenance/Care ..........................................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 inuence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.

WARN INDUSTRIES PAGE 3 80565A1
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. TOOLS REQUIRED
• 3/8" Ratchet and 3-1/2" extension
• Sockets: 10mm, 12mm, 13mm
• Wrenches: 13mm
• Flat Blade Screwdriver
I. PARTS LIST
 Ref Description Qty
A1 Plow Mounting Plate 1
B1 Flange Hd M8-1.25 x 30mm 6
B2 Flat Washer 5/16” 4
B3 Lock Nut M8 4
B4 Spacer 5/16x3/8x3/4 Alum 2
C1 Tab Plow RH Jogged 1
C2 Tab Plow LH Jogged 1
C3 Pin, Plow Retaining 2

WARN INDUSTRIES PAGE 4 80565A1
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure2
Figure3
Figure4
III. INSTALLATION
1. Remove the front skid plate. Use a at blade
screw driver to remove the plastic rivets and a
10mm socket to remove the small shoulder bolts
securing plate to front bumper.
2. Use 12mm socket and ratchet to remove the
lower bumper bolts (Figure 3). Remove both
bolts shown on both sides of bumper. The bot-
tom two bolts will be replaced with fasteners pro-
vided in this kit.
3. Use a 12mm socket and ratchet to loosen the
top bumper bolts (Figure 4). These bolts secure
the rear part of the front bumper and rack as-
sembly. Once loosened the lower section of
front bumper will rotate away from the frame.

WARN INDUSTRIES PAGE 5 80565A1
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure5
Figure7
Figure6
III. INSTALLATION cont.
4. Pull the lower section of the front bumper away
from the vehicle frame enough to allow plow
mounting bracket to pass through (Figure 5).
The bumper should only be pulled out enough to
allow the bracket to t into the frame as the front
body plastic is secured to the bumper.
5. The bracket will need to be carefully moved in
bumper and over front skid pan brackets.
6. Loosely secure the Plow Mount to the anges
on front bumper tubes (Figure 6). These are the
same tabs used to secure the winch mount to
the front bumper.
Install the M8 bumper mounting bolts that secure
the front pumper to the vertical tubes shown in
Figure 3. These are the tubes that the mount is
fastened to. Install the fasteners loosely until all
fasteners have been installed.
7. Now the rear tabs of mount need to be secured
to the lower frame (Figure 7). An aluminum
spacer must be installed between the rear tab
and the lower bumper tube on each side of
frame. Install the M8 x 30mm ange head bolts
provided in this kit to secure the mount, spacers,
and bumper to the frame.

WARN INDUSTRIES PAGE 6 80565A1
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure8
III. INSTALLATION cont.
8. All bumper and plow mounting bolts must now
be tightened securely. Secure all M8 bolts to 20
N-m (15 -lb.)
9. Reinstall the front skid pan with the original fac-
tory fasteners. The small shoulder bolts may be
reinstalled with a 10mm socket and extension by
passing it through the large hole on the side of
the mount.
10. Finally install the plow mounting tab to your Plow
Tube Assembly.
11. Install these loosely on the plow with the fasten-
ers provided with the plow. Tighten the fasten-
ers after the plow is assembled and installed in
the mount per the plow assembly instructions.

WARN INDUSTRIES PAGE 7 80565A1
©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 OPERA-
TOR INJURY OR DEATH. DOUBLE CHECK THAT
ALL BOLTS ARE SECURELY TIGHTENED PRIOR
TO USE.
WARNING
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 ELEC-
TRICAL CABLES. AVOID AREAS WHERE THE
WIRING COULD BE PINCHED WHEN COM-
PONENTS ARE REINSTALLED. FAILURE TO
DO SO CAN RESULT IN PRODUCT FAILURE
WHICH CAN LEAD TO VEHICLE DAMAGE AND
OPERATOR INJURY OR DEATH.
IV. MAINTENANCE/CARE
1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hard-
ware 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 HARDWARE.
NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE TO FOLLOW THIS
WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.