Warn 95160 User manual

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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 Fax: [phone]
INSTALLATION INSTRUCTIONS
FRONT PLOW MOUNT KIT
Part Number: 95160 and 98678
Application: 2015+ Polaris 570
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, theWinch 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 thisWARN 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.

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 95162A1
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 thisWARN product to your vehicle.
• Always put the end of the actuator cable through the slot in theTermination 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.
TABLE OF CONTENTS
Tools Required.............................................................................................................................page 2
Torque Specications................................................................................................................page 2
Parts List.........................................................................................................................................page 3
Installation ................................................................................................................................page 4-8
Maintenance/Care......................................................................................................................page 8
TOOLS REQUIRED
• 1/2 Socket
• 1/4” drive socket wrench
• 13 mm socket
• 13 mm wrench
• 1/4” drive , 10 mm deep socket
• 5mm allen
• Wire cutters
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
FASTENER SIZE FASTENER TORQUE
lb-ft (N.m)
1/4" 8 (11)
5/16" 17 (23)
3/8" 30 (40)
7/16” 48 (66)
1/2" 74 (100)
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)
M4 (2) 3
M5 (4.5) 6
M6 (7.5) 10
M8 (18) 25
M10 (37) 50

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 95162A1
PARTS LIST
Item Part Number Qty Description
1 79226 1 Right Hand Front Plow Mount Bracket
2 95167 1 Hardware Kit (not shown)
3 79225 1 Left Hand Front Plow Mount Bracket
4 95161 1 Front Plow Mount
5 95158 1 Right Hand Support Bracket
6 95159 1 Left Hand Support Bracket
1
4
5
6
3

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INSTALLATION INSTRUCTIONS
1. Using a T27 Torx remove the four torx bolts on the front of
the vehicle. Repeat for other side.
2. Remove the lower front plastic. Repeat for other side.
3. Using a 1/2” socket, remove the two 5/16” ange head bolts
below tow hook.
Figure 1
Figure 2
Figure 3

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 95162A1
INSTALLATION INSTRUCTIONS
4. Install the front plow mount bracket using two 5/16” bolts
and washers provided in kit. Do not tighten at this time.
5. Install two M6 u-bolts with four M6 lock nuts provided in
hardware kit. Do not tighten at this time.
6. Remove the zip tie fastening wire harness to the vehicle
frame.
Figure 4
Figure 5
Figure 6
Front Plow
Mount

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7. Install winch mount using only the top two M8 ange head
bolts provided.
Relocate wire harness in an appropriate location.
8. Place the right and left support brackets into place and bolt
into location using three M8 ange head bolts and two lock
nuts on each side.
9. At this point, torque all hardware to the specied ratings on
page 2.
NOTE: A 1/4” drive socket wrench and a deep 10mm
socket may need to be used to access and torque
the M6 lock-nuts on the u-bolts. See Figure 9 for
reference.
Figure 7
Figure 8
Figure 9
Winch Mount

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10. Reinstall lower front plastic re-using the torx screws removed
in step 1.
NOTE: You may need to trim the lower front plastic for
clearance of plow mount and arms.
11. Attach left and right puck ange to the plow push tube
assembly as shown. Flanges should be mounted internally
with pucks facing inward.
12. Install two M6 socket head bolts to front plow mount as
shown.
Figure 10
Figure 11
Figure 12

©2015 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 95162A1
13. Slide push tube assembly into front plow mount pockets.
14. Insert the 3/8” retaining pins (each side).
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 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 13
Figure 14