Warn 106308 User manual

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 106448A0
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
Front Bumper
Part Number: 106308
Application: 2020 Polaris RZR PRO
GENERAL SAFETY PRECAUTIONS
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always 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.
• 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 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.
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 of Warn Industries Inc. 2 106448A0
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.
TABLE OF CONTENTS
Tools Required.............................................................................................................................page 2
Torque Specications................................................................................................................page 2
Parts List.........................................................................................................................................page 3
Installation ................................................................................................................................page 4-7
Maintenance/Care......................................................................................................................page 7
TOOLS REQUIRED
- Metric wrenches
- Metric sockets
- Air reciprocating saw or a single hack saw blade.
NOTICE
EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper.
• Never attach tow bars directly to the bumper. Damage to bumper may occur. WARN bumpers are not designed to be used for at towing. Consult with the manufacturer of your tow bar system for the proper vehicle tow
bar brackets..
Read installation and operating instructions thoroughly.
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)
BEFORE YOU BEGIN
* This kit is designed to use AXON and VRX long drum winches only

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PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
A1 106319 BUMPER BASE 1
A2 106318 BUMPER SHELL 1
A3 28885 FAIRLEAD PLATE 1
ITEM PART NUMBER DESCRIPTION QTY
B1 93078 M10 HEX HD BOLT 2
B2 69807 M10 NYLOCK NUT 2
B3 82923 M6 HEX HEAD BOLT 2
B4 102248 PLASTIC PLUG 4
B5 93104 M8 HEX HEAD BOLT 4
B6 37533 M6 NUT 2

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 106448A0
Figure 2
Figure 3
INSTALLATION INSTRUCTIONS
1. Release the grille by pulling down on the two top tabs.
2. Carefully remove grille by tipping grille forward and pulling
out until bottom tabs are clear of front fascia and bumper.
3. Remove the four torx head screws from the center bumper
plastic.
4. Remove the two torx head screws on each side of the
bumper plastic.
5. Carefully unsnap plastic fascia, starting from center and pull
away from vehicle. Once removed, set on a clean and stable
surface for later trimming.
Figure 1

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 106448A0
6. Remove the two push pull plastic fasteners. NOTE: You will
not be reusing.
7. Remove the four center hex head bolts securing bumper
bracket and bull bar to vehicle. NOTE: Retain bolts for later
use.
8. Remove bracket and bull bar assembly completely from
vehicle. NOTE: You will not be reusing.
9. Trim front plastic fascia.
a. Remove the top two metal threaded nut clips from the
plastic.
b. With a hack saw blade or utility knife, carefully cut
notches about 3/8” wide and a 1/2” long to the inside
of the nut clip holes. NOTE: Be careful not to cut into the
nut mounting holes as you will need to remount the
fascia.
Figure 3
Figure 4
Figure 5
Removed nut clips
Cut out notch

©2016 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 106448A0
10. Place the new bumper mount (A1) into position.
11. Line up the bumper mount mounting holes with the vehicle
mounting holes and secure to the front of the vehicle using
the four factory hex head bolts.
12. Secure each top corner of the bracket to the vehicle using
one M10 bolt (B1) and nut (B2). TIP: Use a 15mm socket on
the front of the bolt and a 17mm wrench on the rear nut to
make this install a little easier.
13. Replace the trimmed plastic fascia over the mount and
snap back into position. NOTE: The slots you trimmed in
the plastic should align with the bracket to allow enough
clearance for the plastic to sit in its original position.
14. Reinstall the two side factory torx head screws (each side).
15. Slide the bumper shell over the D-ring loops in mount and
align mounting holes.
16. Install your fairlead to the fairlead plate (A3) using hardware
supplied in the winch kit.
A1
Figure 6
Figure 8
B1 & B2 B1 & B2
Factory bolts
Figure 7

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17. Place fairlead bracket assembly on top of the bumper shell,
aligning holes.
18. Set the winch on top of the bracket.
19. Locate the winch access holes on the bottom of the bumper
shell.
20. Using a 13mm socket and extension, loosely install the
four M8 bolts (B5) {included in this kit} along with four lock
washers {included in the winch kit}. IMPORTANT: Do not use
the winch mounting bolts supplied in the winch kit, as they
will not be long enough.
21. Attach the bumper shell using the supplied M6 socket head
screws (B3) and M6 nuts (B6) and the factory torx head
screws.
22. Complete winch wiring using your winch installation
instructions.
23.. Tighten winch hardware as well as all other hardware at this
time.
24. Complete your winch wiring per your winch installation
instructions.
25. Install plastic plugs (B4) in winch bolt access holes.
Your installation is complete.
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 9
Factory torx bolts
B3 and B6