Warn 91280 User manual

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 91281A0
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
FRONT PLOW MOUNT KIT
Part Number: 91280
Application: Polaris Sportsman 400, 500, 800
GENERAL SAFETY PRECAUTIONS
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
• 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 operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
• Always plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
• Never operate the vehicle on slopes greater than 10 degrees with the plow installed.
• Never stand or ride on the plow.
• Always stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
• 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 this WARN product with damaged or missing parts.
• Always 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.
• Always drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
• Always 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.
• Never raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
• Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
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 91281A0
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.
• 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.
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.
BEFORE YOU BEGIN
TABLE OF CONTENTS
Tools Required.......................................................................................................page 2
Torque Specications............................................................................................page 2
Parts List................................................................................................................page 3
Installation......................................................................................................... page 4-6
Maintenance/Care................................................................................................page 6
• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
• Always use extreme caution when cutting and trimming during tting.
TOOLS REQUIRED
- 13mm socket and end wrench
- 1/2” socket and end wrench
- 3/8 Drive Ratchet
TORQUE SPECIFICATIONS
1/4 (6mm) 8 lb. ft. (10.8 N-m)
5/16 (8mm) 17 lb. ft. (12.5 N-m)
3/8 (10mm) 30 lb. ft. (40.7 N-m)
7/16 (11mm) 50 lb. ft. (67.8 N-m)
1/2 (13mm) 75 lb. ft. (101.7 N-m)

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 91281A0
PARTS LIST
Reference Part Number QTY Description
A1 91279 1 Plow Mount Assembly
A2 91272 1 Left Brace
A3 91273 1 Right Brace
A4 79225 1 Left Plow Bracket
A5 79226 1 Right Plow Bracket
B1 21331 2 5/16-18 x 1” bolt
B2 1324 2 5/16” washer
B3 1402 2 5/16” lock washer
B4 78648 2 M8 x 20mm ange bolt
B5 65970 4 M8 x 25mm ange bolt
B6 71588 6 M8 ange nut
B7 79712 2 Retaining Pin
C1 Not included 1 Winch Mount

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 91281A0
INSTALLATION INSTRUCTIONS
1. Remove lower front bumper plastic cover.
2. Remove the two bolts shown.
3. Remove the lower winch mount fasteners shown in gure 3.
Figure 1
Figure 2
Figure 3
Remove Bumper Cover

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 91281A0
INSTALLATION INSTRUCTIONS
4. Place the plow mount assembly (A1) into position and
install lower fasteners (B1, B2, B3) as shown in gure 4. Do
not tighten fasteners at this time.
5. Install upper fasteners (B4, B6) as shown in gure 5. Do not
tighten at this time.
6. Install left and right braces (A2, A3) using fasteners (B5,
B6) as shown in gure 6.
Figure 4
Figure 5
Figure 6

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 91281A0
MAINTENANCE / CARE
7. Tighten all fasteners to torque specication supplied.
8. Install bumper cover, removed in step 1. Note lower edge
of plastic may need to be trimmed to allow more access for
the plow anges when installing plow to vehicle mount.
9. Install left and right plow bracket (A4, A5) to plow push
tube assembly. Note: the brackets are installed to the
inside of the push tube tabs. See gure 7.
1. Inspect all parts on the plow, plow mount, and related hardware prior to each use. Replace all hardware that appears
rusted or deformed.
2. Inspect all nuts and bolts on the plow, plow 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 7