Warn 106822 User manual

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 106859A0
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
Winch Mount Bumper
Part Number: 106822
Application: 2020 Polaris General
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 Know Your Winch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, 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 this WARN 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.
GENERAL SAFETY PRECAUTIONS

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 106859A0
Tools Required.................................................................. page 2
Parts List.............................................................................. page 3
Torque Specications..................................................... page 3
Installation ......................................................................page 4-8
Maintenance/Care........................................................... page 9
EQUIPMENT DAMAGE
• Never tow vehicle by attaching a tow bar to the eyelets on the bumper.
• Do not 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.
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.
NOTICE
CAUTION
NOTES
TABLE OF CONTENTS
• Standard wrenches and sockets
• Metric wrenches and sockets
• Pneumatic reciprocating saw
TOOLS REQUIRED

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 106859A0
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) B4
PARTS LIST
TORQUE SPECIFICATIONS
Item PN Description Qty.
A1 106824 UPPER BUMPER MOUNT 1
A2 94890 SUPPORT MOUNTING BRACKET 1
A3 106826 LOWER BUMPER MOUNT 1
A4 106830 BUMPER SHELL 1
A5 28885 FAIRLEAD PLATE 1
Item PN Description Qty.
B1 83474 M8 LOCK WASHER 4
B2 93104 M8 X 25MM HEX HEAD BOLT 4
B3 71588 M8 LOCK NUT 8
B4 65970 M8 X 25MM FLANGE HD BOLT 8
B5 87232 M10 LOCK NUT 4
B6 69954 M10 X 35MM HEX HEAD FLANGE BOLT 4
B7 79465 M12 FLANGE LOCK NUT 4
B8 79464 M12 HEX HEAD FLANGE BOLT 4
B9 102248 PLASTIC PLUG 4

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 106859A0
INSTALLATION INSTRUCTIONS
1. Remove the front bumper.
a. First pull the plastic tube caps from the front of the
bumper.
NOTE: If you are changing from a Polaris winch to
a WARN winch bumper mount you will also need to
remove the hook and fairlead at this time.
b. Remove the upper grille by depressing the two grille
tabs.
c. Remove the two bolts and nuts that hold the tube bum-
per to the vehicle. TIP: Place a 15mm wrench behind the
grill to hold on to the nuts while using a ratchet and 15mm
socket on the front side.
d. Remove the lower two bumper bolts and nuts using a
15mm socket.
2. After removing the bumper, remove the nut plate.
Located behind the two lower bumper bolts by lifting up
and sliding o the metal ange.
Figure 1
Figure 2
Figure 3
Plastic tube cap
Hook and Fairlead
Upper grill tabs
Upper hardware
Lower hardware

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 106859A0
INSTALLATION INSTRUCTIONS
3. Remove the four push pull pin fasteners and remove the
front center plastic. Save hardware for later step.
4. Install support mounting bracket (A2).
TIP: For this step, it may be more clear to refer to the
exploded view on page 3 for part A2.
a. Position the bracket (A2) behind the sheet metal ange
just behind the plastic grill.
b. Install two ange head 10mm bolts (B6) through the
bracket and sheet metal ange.
c. NOTE: The mounting holes vary in size. The size of the
mounting hole determines the size of the bolt for this
step.
Install the two ange head bolt (B8 OR B6) up through
the frame and through the bracket.
d. Secure with two ange head nuts (B5) or (B7) depending
on which bolt you used.
Figure 5
Figure 6
B8 or B6
B7 or B5
B6
A2
Figure 4

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INSTALLATION INSTRUCTIONS
5. Attach the lower bumper bracket (A3) to the vehicle
using the M8 ange bolts (B4) and lock nuts (B3).
6. Attach the upper bumper mount by placing over the
previously installed M10 bolts.
7. Thread the supplied ange lock nuts (B5) on but do not
tighten yet.
8. Continue installing, using two M12 hex head bolts (B8),
lock nuts (B7) and the two lower M8 hex head bolts (B4)
and lock nuts (B5).
Once all the hardware is installed, tighten ALL hardware
at this time.
Figure 9
Figure 8
A1
B5
B4 & B3
B8 & B7
B4 & B5
Figure 7

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 106859A0
INSTALLATION INSTRUCTIONS
Due to winch mount interference, you will need to
modify the front center plastic before reinstalling on the
vehicle.
9. Position front center plastic on vehicle. Mark where the
winch mount interferes with plastic. NOTE: Each vehicle
will be slightly dierent, image shown is one option.
10. With plastic on a at and stable surface, carefully use a
pneumatic reciprocating saw or similar to cut the plastic
where marked. NOTE: It can be helpful to cut a smaller
portion out for the rst cut and ne tune the cut after
test tting. The edges can be smoothed with a le or
sanding disc.
11. Reinstall the front center plastic to the vehicle, using the
four push pull pin fasteners.
12. Slide the bumper shell (A4) over the bumper mount,
threading the D-ring loops through the shell. NOTE: Be
sure to align the winch mounting holes in the shell with
holes in the bumper mount.
Figure 12
Figure 13
Figure 10
Figure 11

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 106859A0
INSTALLATION INSTRUCTIONS
13. Install fairlead to fairlead plate (A5) using hardware from
the winch kit.
14. Connect winch wiring cables to winch per winch
installation instructions.
15. Place fairlead plate/fairlead on top of the bumper, lining
up winch mounting holes.
16. Place the winch on top of the fairlead plate, aligning
mounting feet with holes.
17. Using the access holes and a 13mm socket with
extension, secure winch using four non ange M8 hex
head bolts (B2) and lock washers (B1). TIP: Lift one corner
of the winch slightly as you begin to install your rst bolt.
Once all the winch bolts are installed, torque the winch
bolts to proper torque specications on page 3.
18. Secure bumper using two M8 ange head bolts (B4) and
lock nuts (B3).
19. Plug access holes with supplied plugs (B9).
Figure 15
Figure 16
Figure 14
B2 & B1
B4 & B3

©2019 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc. 9 106859A0
INSTALLATION INSTRUCTIONS
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDER-
STAND 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 17
20. Attach the hook and hook strap to the winch rope.
21. Complete winch wiring per your winch installation
instructions from your winch kit.
OPTIONAL: Replacing Polaris Winch with WARN VRX Winch
• Disconnect the battery.
• Disconnect the small wire harness that leads to the contac-
tor (remove zip tie).
• Disconnect ground wire from winch.
• Remove power cables that run from the battery to the top
of the contactor.
• Remove the winch mounting bolts.
• Slide the winch out the drivers side of vehicle by exing the
radiator hose out of the way.
At this point you may choose to wire the Warn contactor or use
the existing electrical that came with the vehicle.
• Remove the contactor bracket from the Polaris winch
leaving everything intact.
• Remove the two short wires that run from the
contactor to the winch motor (these will be replaced by
the wires you attached to the Warn winch early on).
• Remove the four bolts that hold the factory mount in
place.
• Remove the winch mount and drill two holes mount
matching the contactor bracket holes.
• Once drilled bolt the bracket to the mount and reinstall
to the factory location as shown in picture.
• Route the wires you installed on the WARN winch to
the contactor and attach per Warn winch installation
instructions. Coil the excess wire and zip tie up and out
of the way.
• Connect the power and ground lead wires back onto the
contactor from there original location.
• Plug the small harness back to the contactor that you
previously removed.
• Reconnect battery.
Installation is complete.