Warn 100960 User manual

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 1 101246A0
WARN INDUSTRIES, INC. 12900 S.E. Capps Road,
Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: [phone]
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
International Fax: [phone]
INSTALLATION INSTRUCTIONS
PLOW MOUNT KIT
Part Number: 100960
Application: Polaris Sportsman XP, SP, X2 Touring
GENERAL SAFETY PRECAUTIONS
WARNING
Impact and Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH
• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
• 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, 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:
o Across any sharp edges.
o Through or near moving parts.
o 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 instructions.
• Always operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
• Always plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
• Never operate the vehicle on slopes greater than 10 degrees with the plow installed.
• Never stand or ride on the plow.
• Always stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
• Always perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
• Always replace all worn or damaged parts before operating.
• Never operate thisWARN product with damaged or missing parts.
• Always 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.
• Always drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
• Always 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.
• Never raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
• Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
Read installation and operating instructions thoroughly.
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 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 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.

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 2 101246A0
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 thisWARN product to your vehicle.
• Always put the end of the actuator cable through the slot in theTermination 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.
CAUTION
Moving Parts Entanglement Hazard
FAILURETO OBSERVETHESE INSTRUCTIONS COULD LEADTO 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.
TABLE OF CONTENTS
Tools Required.............................................................................................................................page 2
Torque Specications................................................................................................................page 2
Parts List.........................................................................................................................................page 3
Installation ...............................................................................................................................page 4 -6
Maintenance/Care......................................................................................................................page 6
TOOLS REQUIRED
- Standard wrenches
- Standard sockets
- Hacksaw Blade with Handle (ne tooth)
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
FASTENER SIZE FASTENER TORQUE
lb-ft (N.m)
1/4" 8 (11)
5/16" 17 (23)
3/8" 30 (40)
7/16” 48 (66)
1/2" 74 (100)
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)
M4 (2) 3
M5 (4.5) 6
M6 (7.5) 10
M8 (18) 25
M10 (37) 50

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 3 101246A0
PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
A1 100957 PLOW WELDMENT 1
A2 79225 PLOW LH BRACKET 1
A3 79226 PLOW RH BRACKET 1
B1 89084 M8 HEX HEAD BOLT 4
B2 71588 M8 FLANGE NUT 4
B3 79712 3/8 SAFETY PIN 2
B4 63010 FENDER WASHERS 2
B5 2002 5/16 LOCK NUTS 2
B6 1324 5/16 FLAT WASHERS 2
B7 7355 5/16 CARRIAGE BOLTS 2

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 4 101246A0
BEFORE YOU BEGIN: A WARN winch mount is required for plow
mount installation.
1. Remove the grill and the lower front plastic.
2. Install WARN winch mount and winch, following winch and
mount instructions.
INSTALLATION INSTRUCTIONS
Figure 1
Figure 2
Figure 3

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 5 101246A0
INSTALLATION INSTRUCTIONS
3. Insert the two carriage bolts ( B7) through the backside of
the winch mount as indicated in photo.
4. Slide plow mount into position, between the two tabs on the
front lower frame.
5. Align the holes in the front of the plow mount over the
carriage bolts previously installed and secure with washer
(B6) and nut (B5). Do not tighten at this time.
6. Mark lower outter corners of front plastic to cut.
Bolts (3) each side
Lower frame tab
Fairlead
Carriage bolts
Figure 4
Figure 5
Figure 6

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 6 101246A0
7. Using a cutting tool of choice, remove the lower section of
plastic.
NOTE: The modication of front plastic will vary depending
on which Sportsman model you purchased.
8. Reinstall the top portion of plastic using the two screws
previously removed in step 1. Your Installation is now
complete.
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.
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.
Figure 7
Figure 8