Warn 82530 User manual

WARN INDUSTRIES PAGE 1 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
PART NUMBER: 82530
APPLICATION: 2006+ BRUTE FORCE 650i
WARNING
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ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
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aysys
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ys 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.
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ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye
injury.
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ys use extreme caution when cutting and trimming during fitting.
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ys remove jewelry and wear eye protection.
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er lean over battery while making connections.
NeNe
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ver rer r
er rer r
er routout
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oute electrical cables:e electrical cables:
e electrical cables:e electrical cables:
e electrical cables:
oAcross any sharp edges.
oThrough or near moving parts.
oNear parts that become hot.
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ys insulate and protect all exposed wiring and electrical terminals.
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ys install terminal boots as directed in installation instructions.
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ys use appropriate and adequate care in lifting components into place.
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ys insure components will remain secure during installation and operation.
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ys tighten all nuts and bolts securely, per the installation instructions.
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ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
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ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
NeNe
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erer
er operate the vehicle on slopes greater than 10 degrees with the plow installed.
NeNe
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er stand or ride on the plow.
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ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
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ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
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ys replace all worn or damaged parts before operating.
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er operate this WARN product with damaged or missing parts.
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ys 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.
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ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
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ys 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.
Ne
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er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
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ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
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 empha-
size general information worthy of special attention.

WARN INDUSTRIES PAGE 2 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
I. TABLE OF CONTENTS
Tools Required .............................................page 2
Torque Specifications...................................page 2
Parts List .......................................................page 3
Installation................................................. page 4-5
Maintenance/Carepage ............................... page 6
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 influence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.
Notice
Equipment Damage
44
44
4ALWAYS 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.
Never overtighten the j-bolt to the bracket. Doing so will pinch the winch cable against the bracket, damaging the cable.
Always put the end of the actuator cable through the slot in the Termination 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.
III. TORQUE SPECIFICATIONS
1/4 (M6) 8 lb. ft. (10.8 N-m)
5/16 (M8) 17 lb. ft. (12.5 N-m)
M8 U-Bolt 11 lb. ft. (15 N-m)
II. TOOLS REQUIRED
- 3/8” Ratchet and 6” Extension
- Sockets: 10, 13 and 14mm

WARN INDUSTRIES PAGE 3 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
IV. PARTS LIST
Ref.Part Number Qty Description
A1 82573 1 Plow Mount Bracket BF650i
A2 79225 1 Plow Flange Bracket, Left
A3 79226 1 Plow Flange Bracket, Right
A4 82536 1 Bumper Cover Plate BF650i
A5 82537 1 Pan Clamp Plate BF650i
B1 1324 4 Flat Washer 5/16
B2 22491 4 Lock Nut M8
B3 79604 2 M8 U-Bolt 35x48 mm
B4 79461 2 Bolt M10-1.25x20 Hex
C1 79712 2 Retaining Pin Plow L-Wire
A5 B3
B4
C1
A2
A3 A4
B2
B1
A1

WARN INDUSTRIES PAGE 4 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 1
Figure 2
Figure 3
V. INSTALLATION
Remove Front Skid Pan
1. Use 10mm socket to remove the M6 flange
head screws that secure the front pan to
bumper and frame. (Figure 1)
2. Install the small skid pan clamp (Figure 2) plate
to secure the front of the bottom skid pan.
Secure this plate and the skid pan with the
original M6 factory fasteners.
Install Plow Mount
1. Use 14mm socket to remove the M10 factory
bumper bolts. (Figure 3).
2. The upper bumper bolts may need to be loose
to allow the lower bolts to be removed and
reinstalled.
3. Position Plow Mount on front bumper (Figure 4).
Use M10-1.25x20mm bolts provided to secure
the mount at frame.
4. Position M8 U-Bolts over bumper tubes and
insert into mount. (Figure 5).
5. Secure U-Bolts with M8 lock nuts.

WARN INDUSTRIES PAGE 5 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 5
Figure 6
INSTALLATION CONT.
Figure 4
Install Bumper Cover Plate
1. The small formed plate included in this kit is
intended to cover the front bumper skid pan
mounting tabs.
2. Position it on the mounting tabs, as shown in
Figure 6 and secure it with the original factory
fasteners.
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 7).
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 7

WARN INDUSTRIES PAGE 6 82531A0
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
VI. MAINTENANCE/CARE
• Inspect all metal parts on the plow, plow mount, and related hardware. Replace all parts that appears
rusted or deformed prior to use.
• Inspect all nuts and bolts on the plow, plow mount, and related hardware prior to each use. Tighten all
nuts and bolts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced
immediately.
• Check all cables prior to use. Replace cables that are worn or frayed.
• Check all moving and rotating parts. Remove debris that may inhibit the part from moving freely.