Warn 87722 User manual

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 87731A0
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
BUMPER KIT
Part Number: 87722
Application: Polaris Ranger RZR 900 2011+
GENERAL SAFETY PRECAUTIONS
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT 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,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:
•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.
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.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 87731A0
NOTICE
EQUIPMENT DAMAGE
• AlwaysrefertotheInstallationandSpecicationGuide,suppliedinthewinchkit,forallwiringschematicsandspecicdetailsonhowtowirethisWARNproducttoyourvehicle.
Read installation and operating instructions thoroughly.
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.
NOTES
TABLE OF CONTENTS
Parts List................................................................................................................ page x
Tools Required....................................................................................................... page x
Torque Specications............................................................................................ page x
Installation............................................................................................................. page x
Tips/Troubleshooting ............................................................................................ page x
Maintenance/Care................................................................................................ page x
NOTE: This bumper includes mounting holes for WARN winch and trail lights, which are sold separately
TOOLS REQUIRED
- 13mm, 9/16” socket
- 7/16” deep socket
- 13mm wrench
- 9/16” wrench
- socket wrench
- Phillips screw driver
- 10mm socket
- 10 mm wrench
TORQUE SPECIFICATIONS
1/4 8 lb. ft. (10.8 N-m)
5/16 17 lb. ft. (12.5 N-m)
3/8 30 lb. ft. (40.7 N-m)
7/16 50 lb. ft. (67.8 N-m)
1/2 75 lb. ft. (101.7 N-m)

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 87731A0
PARTS LIST
Part Number Qty Description
A1 1 Bumper
A2 1 Rear Cross Bar
A3 1 Front Armor Plate
A4 1 Cross Bar Support
B1 2 M8 x 1.25 x 20mm Hex Head Bolt
B2 2 5/16” Flat Washer
B3 2 M8 x 1.25 Nylon Lock Nut with Flange
C1 8 3/8-16 x 1” Hex Head Bolt
C2 16 3/8” Flat Washer
C3 8 3/8 - 16 Nylon Lock Nut
Part Number Qty Description
D1 4 1/4 - 20 U-Bolt
D2 8 1/4” Flat Washer
D3 8 1/4-20 Nylon Lock Nut
E1 2 3/8 Black Plastic Conduit (not shown)
E2 2 1/4 Black Plastic Conduit (not shown)

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 87731A0
INSTALLATION INSTRUCTIONS
1. Remove winch mount access cover on front of vehicle
by removing four fasteners, as show, in Figure 1.
Remove left and right wheel well guards at this time.
2. Locate mounting holes to attach front support plate
(A3) to frame as shown in Figure 2.
3. Attach front support plate (A3) to frame, as shown
in Figure 3. Use M8 x 1.25 x 20mm hex head bolts
and 5/16” at washers on front side and M8-1.25
nylon lock nuts on back side. Loosely secure hard-
ware using 13mm socket and wrench.
Figure 1
Figure 2
Figure 3
Remove left
and right
wheel well
guards
Remove
winch mount
access cover

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 87731A0
INSTALLATION INSTRUCTIONS
4. Install rear crossmember behind two vertical frame
supports as shown in Figure 4. Gusseted corner of
crossmember should face up. Use 1/4-20 u-bolts,
atwashers and lock nuts to loosely attach to frame.
A 7/16” deep socket will be used to tighten in place
later.
5. Set bumper on top of front armor plate as shown
in Figure 5. Loosely attach with four 3/8-16” hex
head bolts, at washers and lock nut. A at washer
should be used under head of bolt and on top of
locknut. A 9/16” socket and wrench can be used to
loosely secure. This will help you to level the cross-
member before you tighten the hardware.
Figure 4
Figure 5
Figure 6

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 87731A0
INSTALLATION INSTRUCTIONS
6. Align holes in frame mount bracket of bumper weld-
ment with holes in wings of rear crossmember, as
shown in Figure 7. Loosely attach with four 3/8-16”
hex head bolts, at washers and lock nut. A at
washer should be used under head of bolt and on
top of locknut. A 9/16” socket and wrench can be
used to loosely secure.
7. Tighten all hardware, making sure that u-bolts are
not binding on frame tubes. Check for adequate
clearance with radiator hose and rear crossmember
on passenger side of vehicle.
8. After all other fastners have been tightened, install
cross member support bracket (A4). It attaches to
the back side of the (A2) and then to the frame of
the vehicle. Refer to the exploded view for attach-
ment.
Torque u-bolt nuts, as shown in Figure 4, to recom-
mended specications of 8lb. ft (10.8 N-m). Torque
M8 x 1.25 hardware on bottom of front armor plate,
as shown in Figure 3, to recommended specica-
tions of 17lb.ft. (12.5 N-m).
9. Torque 3/8-16 hardware on bottom of bumper
weldment and joint between frame brackets/rear
crossmember, as shown in Figure 5 and 6 to recom-
mended specications of 30 lb. ft. (40.7 N-m).
10. See Figure 9 for view of completed installation.
Figure 7
Figure 8
Figure 9

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 87731A0
INSTALLATION INSTRUCTIONS
VI. Optional Winch and Light Installation
(Refer to these tips if winch and /or lights are
added to bumper)
1. WARN winch mounting holes are shown in Figure
10. Pull yellow cable through front hole and blue
cable through rear hole after sliding conduit over top
both cables. 1/4” ID conduit is to be used for RT/
XT25 winches; 3/8” ID conduit is to be used for RT/
XT30 winches.
2. If no winch is mounted on bumper the set of holes,
as shown in Figure 10, can be used to mount a set
of lights on top of bumper. If winch is used, there
are holes on bottom of bumper, as shown in Figure
11, that can be used to mount a set of lights.
RT/XT 25 and 30
winch mount holes
Figure 10
Figure 11
Light mount
holes
Hole for blue
cable
Light mount
holes
Bumper to be used with 2500 and 3000 lb. winches
only. Do not attempt to mount 4000 lb. winch on this
application, vehicle damage and operator injury or
death may result.
WARNING

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 87731A0
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.
MAINTENANCE / CARE
1. Inspect all parts on the bumper and related hardware prior to each use. Replace all hardware that appears rusted
or deformed.
2. Inspect all nuts and bolts on the bumper, 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 moving or rotating parts. Remove debris that may inhibit the part from moving freely.
FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE BUMPER CAN RESULT IN PRODUCT FAILURE WHICH MAY
RESULT IN VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH. DOUBLE CHECK THAT ALL BOLTS ARE SE-
CURELY TIGHTENED PRIOR TO USE.
WARNING
WARNING
PERFORM REGULAR INSPECTIONS ON THE BUMPER AND RELATED HARDWARE. FAILURE TO FOLLOW THIS
WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.