Warn 80360 User manual

WARN INDUSTRIES PAGE 1 80361A1
©2009 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
damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or
personal injury.
Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips.
Flying chips can cause eye injury.
Always use extreme caution when cutting and trimming during fitting.
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: 80360
Application: Kawasaki Brute Force
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 identifies 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.

WARN INDUSTRIES PAGE 2 80361A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Notice
Equipment Damage
Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific 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
Caution
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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 influence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.

WARN INDUSTRIES PAGE 3 80361A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. Tools Required
• Ratchet and Extension
• Sockets: 10mm, 14mm, 1/2”
• Wrenches: 1/2”
• Flat Blade Screwdriver
I. Parts List
Ref Description Qty
A1 Plow Mounting Plate 1
B1 5/16-18 x 1 1/8” x 1 3/4” U-bolt 2
B2 5/16” Flat Washer 4
B3 5/16-18 Lock Nut 4
B4 M10-1.25 x 20mm Flange Head 2
C1 Plow Mount Bracket, Right 1
C2 Plow Mount Bracket, Left 1
C3 Plate winch spacer 2
C4 Pin, Plow Retainer 2
C4
C3
B2
C2
B4
B3
B4
C1
A1
B1

WARN INDUSTRIES PAGE 4 80361A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
III. INSTALLATION
1. Loosen the front bottom skid plate by
removing the front two 6mm bolts, Figure 2.
Keep the 6mm bolts for reinstallation of the
skid plate. Skid plate will not be removed from
vehicle, only will be rotated down. This will
allow room for winch plate installation.
2. Loosen and remove lower bumper bolts M10.
New bolts (B4) provided in this kit, Figure 3.
3. Place plow mount in bumper. Align holes on
mounting tabs with the holes in bumper and
frame. Install M10x20 flange bolts (B4)
supplied, but do not tighten at this time.
Figure 4.
4. Secure plow mount to frame tubes with 5/16
u-bolts (B1) and washers (B2) and nuts (B3)
as shown in Figures 1 & 5.
Tighten all 5/16” fasteners to 12 N-m (9ft.lb.).
Tighten M10 bolts to 27 N-m (20ft-lb.)
Figure 3
Figure 4
Figure 2 Loosen Front Skid Plate
Remove Skid
Install the plow mounting tabs.
1. The plow mounting tabs supplied in this kit
must be secure to the plow in the position
shown. (Figure 4b).
2. Loosely install the M10 bolts from the plow kit.
Attach the plow to the plow mount and then
secure the plow mounting tabs. This will insure
the best fit for your vehicle.
Figure 4b

WARN INDUSTRIES PAGE 5 80361A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 5
Front Tube Guards
A1
1. Place winch mount in front of bumper by
rotating it sideways and then inserting it though
front center of bumper, Figure 6.
2. Rotate the mounting plate into location, Figure
7. Center the plate between the two front tube
guards and align winch plate holes with plow
mount holes.
3. Install shim plates (C3) under the front of winch
mount. Figure 7.
Attach the mounting plate (A1) by sliding the
supplied 5/16” U-bolts (B1) and (B2) around the
tubes and through the plate, Figure 8. Fasten
the U-bolts with the supplied washers (B3) and
nuts (B4), ensuring that the plate sits flush
against the front and rear contact surfaces.
Tighten all 5/16” fasteners to the recommended
torque value of 12 N-m (9 ft-lbs).
Figure 7 Place Winch Mounting Plate into Location
If installing winch mount:
Figure 6
Shim Plates

WARN INDUSTRIES PAGE 6 80361A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 8 Fasten Winch Mounting Plate
Rear Contact Surface
B1
B2
Front Contact Surface
B3 & B4
Figure 9 Install Winch and Roller Fairlead
Install Winch From Left
Roller Fairlead
4. Install winch from the left side of the vehicle, as
sitting on the vehicle, Figure 9. Fasten winch
with hardware supplied with the winch. Mount
the winch so that the motor faces the right side
of the vehicle. Tighten the bolts to a
recommended torque of 17 N-m (12 ft-lb).
Also attach roller fairlead to the winch mounting
plate, Figure 9, using two hardware provided in
the winch kit. See instructions included in
winch kit for recommended torque.
5. Switch the winch clutch to freespool. Manually
feed the winch cable through the roller fairlead.
Attach the clevis hook to the end cable loop,
Figure 10. Reinstall front skid plate with original
hardware from step 1 and securely tighten.
6. Complete the winch installation as described in
the winch installation and specification guide
that came with the winch.
Plow and winch mount installation is now
complete and should look like Figure 10.
Figure 10 Complete Winch Installation
Clevis Hook
Front Skid Plate
B2

WARN INDUSTRIES PAGE 7 80361A1
©2009 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 OP-
ERATOR 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
ELECTRICAL CABLES. AVOID AREAS WHERE
THE WIRING COULD BE PINCHED WHEN
COMPONENTS ARE REINSTALLED. FAILURE
TO DO SO CAN RESULT IN PRODUCT
FAILURE WHICH CAN LEAD TO VEHICLE
DAMAGE AND OPERATOR INJURY OR DEATH.
V. 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.
WARNING
PERFORM REGULAR INSPECTIONS ON THE WINCH, WINCH MOUNT, AND RELATED HARD-
WARE. NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE TO
FOLLOW THIS WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.