Warn 101694 User manual

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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 Sales/Customer Service: 1-503-722-3008
International Fax: [phone]
INSTALLATION INSTRUCTIONS
MOUNTING KIT BUMPER
Part Number: 101694
Application: 2013-2019 Can Am Maverick 1000 (2p & 4p)
GENERAL SAFETY PRECAUTIONS
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.
WARNING
Impact and Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH
• Always KnowYourWinch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide toWinchingTechniques, in order to understand your winch and its operations.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never use a jack to support the vehicle.
• Always use jack stands in pairs to support the vehicle.
• Always use jacks or jack stands only on a hard, stable, and level surface.
• Never exceed the rated capacity of a jack or jack stands.
• Always verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle.
• Never work under vehicle before properly securing vehicle.
• 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.
• Always replace all worn or damaged parts before operating.
• Never operate thisWARN product with damaged or missing parts.
• 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 use extreme caution when cutting and trimming during tting.
• Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying chips can cause eye injury.
• Always remove jewelry and wear eye protection.
• Never lean over battery while making connections.
• Never route electrical cables across any sharp edge, through or near moving parts, near parts that become hot.
Read installation and operating instructions thoroughly.

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 106093A0
TABLE OF CONTENTS
Tools Required.........................................................................................................................................................................................................................page 2
Torque Specications............................................................................................................................................................................................................page 2
Parts List.....................................................................................................................................................................................................................................page 3
Installation ............................................................................................................................................................................................................................page 4-6
Maintenance/Care..................................................................................................................................................................................................................page 6
CAUTION
Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO MINOR OR MODERATE INJURY
• Part edges may be sharp!
• Always use proper posture / lifting technique or get lifting assistance while handling and installing product.
Read installation and operating instructions thoroughly.
TOOLS REQUIRED
- Standard and Metric wrenches
- Standard and Metric sockets
- Ratchet
- Extension
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
FASTENER SIZE FASTENER TORQUE FASTENER SIZE FASTENER TORQUE
lb-ft (N.m) lb-ft (N.m)
1/4" 8 (11) M4 (2) 3
5/16" 17 (23) M5 (4.5) 6
3/8" 30 (40) M6 (7.5) 10
7/16” 48 (66) M8 (18) 25
1/2" 74 (100) M10 (37) 50
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 106093A0
PARTS LIST
ITEM PN DESCRIPTION QTY
A1 105943 WLDMNT LH UPPER MOUNT 1
A2 105958 WLDMNT RH UPPER MOUNT 1
A3 105954 BUMPER SHELL 1
A4 105956 SKID PLATE 1
A5 102078 LIGHT BRACKET 1
A6 28885 FAIRLEAD BRACKET 1
ITEM PN DESCRIPTION QTY
B1 93104 M8 X 25MM HEX HEAD BOLT 13
B2 1324 FLAT WASHER 13
B3 22491 M8 LOCK NUT 9
B1 B2 B3

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 106093A0
INSTALLATION INSTRUCTIONS
1. Remove front bumper.
2. Remove the two front screws and ange washers from the
front of the skid plate.
3. Remove the two top bolts and the two lower bolts and nuts
that hold the bumper to the vehicle (each side).
4. Attach the upper portion of the left (A1) and right (A2)
bumper brackets to the vehicle using the top two bumper
Figure 2
Figure 4
Figure 3
Remove
Remove

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 106093A0
INSTALLATION INSTRUCTIONS
mounting bolts previously removed.
5. Install the skid plate (A4) between the frame brackets and
secure to lower bracket hole and frame using one M8 bolt
(B1) and washer (B2) through plate and frame (each side).
6. Loosely secure with washer (B2) and M8 nut (B3) (each side).
Refer to exploded view on page 3.
OPTIONAL: If you purchased the optional light bar, we
recommend installing it to the light bracket before you
install the bumper.
7. Line the winch mounting holes in the bumper shell to the
slots of the frame brackets at this time.
8. Install light bracket (A5) to bumper shell using bolts (B1),
washers (B2) and nuts (B3). Refer to exploded view on page 3.
9. Install the skid plate’s front mounting bolts (B1) washers (B2)
and nuts (B3) to the bumper shell at this time. NOTE: Do
Figure 5
Figure 6
Figure 7
Factory bumper
bolts
Light bracket
installed
A1
A2
A4
B2 & B3
A3
B1 & B2
B1 & B2

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INSTALLATION INSTRUCTIONS
not fully tighten hardware to allow for adjustment.
10. Install the lower corner bumper bolt (B1) and washer (B2)
through bumper and skid plate and secure with washer
(B2) and nut (B3) (each side). NOTE: Do not fully tighten
hardware to allow for adjustment.
11. Attach the fairlead to the fairlead bracket (A6) using the
hardware supplied in your winch kit.
12. Align the fairlead plate mounting holes with the bumper
shell mounting holes.
13. Set the winch on top of the bumper shell, aligning the holes
in the fairlead plate.
Tip: We recommend installing the winch power cables to the
winch before installing to bumper. Follow instructions in
your installation guide supplied with your winch.
WARNING
Do not use the bolts supplied in the winch kit to install winch, as
they will not be long enough.
14. From underneath the bumper shell, install four M8 bolts
(B1) (from this kit) and hand tighten with four lock washers
(from your winch kit).
15. Tighten ALL hardware at this time to torque specication on
page 2.
16. Complete your wiring per your winch installation
instructions supplied with your winch.
Figure 8
Figure 9
B1, B2, B3
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.
B1, B2,
B3