Warn 82459 User manual

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InstructionDisclaimer
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Dennis Kirk provides instructions to help our customers better understand how to install the
products we sell. The instructions are exact copies of what the manufacturer includes with the
product being sold.
That means the quality and accuracy of the instructions is solely dependent on what the
manufacturer produces. We do our best to make the text legible and the pictures viewable.
However, the end result depends largely on the quality of instructions the manufacturer
provides.
Therefore, you will find that some instructions are not of the highest quality. Sometimes text is
hard to read and pictures are not easy to see. At times you will find the overall look of the
instructions to be less than professional. However, we feel it is better to provide what we have
rather than provide nothing at all.
To the best of our knowledge the instructions and application information contained in the
instructions is accurate. However, Dennis Kirk assumes no liability related to any errors that
may be contained in the copy of the manufacturer’s instructions we provide. Buyers are solely
responsible to insure that product use is consistent with their application.
If you have any questions please contact us at [email protected] or
800-969-7501 so we can further assist you regarding additional product information or any other
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Thank you for doing business with Dennis Kirk.

INSTALLATION INSTRUCTIONS
BRAKE ASSEMBLY KIT
PART NUMBER: 82459
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 pos-
sible 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 EQUIP-
MENT DAMAGE. READ AND UNDERSTAND
ALL SAFETY PRECAUTIONS AND OPERATING IN-
STRUCTIONS 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 si nals a hazard
that could cause serious injury or death, if you do not follow recom-
mendations. 1 signals a hazard that may cause minor to moderate injury, if you do not
follow recommendations.
This guide usesINOT/CElto call attention to important mechanical information, and Note: to emphasize
general information worthy of special attention.
WARNING
INJURY HAZARD
Failure
to observe these instructions could lead to severe injury or death
o Always remove jewelry and wear eye protection.
o Never lean over battery while making connections.
o Never route
electrical cables:
-Across any sharp edges.
-Through or near moving parts.
-Near parts that become hot.
o
Always insulate and protect all exposed wiring and electrical terminals.
o
Always install terminal boots as directed in installation instructions.
o
Always tighten all nuts and bolts securely, per the installation and operation.
o
Always perform regular inspections and maintenance on the winch, winch mount and related
hardware. Read
installation and operating instructions thoroughly.
NOTE: Brake holding capacity for this kit is designed to work with a plow. The
brake will not hold to the full capacity of the winch.
NOTE: See WARN
part number 74925 for winch o-ring kit. This kit will upgrade the
winch to be more resistant to moisture and contamination.
WARN INDUSTRIES
PAGE 1 81816AO
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.

'·x,
,i '"
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~' -' ~ 'A
CAUTjO,t,l
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Moving Parts Entanglement Hazard
Failure to observe these Instructions could lead to minor or moderate injury.
D Always take time to fully read and understand the installation and Operations Guide included with this product.
D Never operate this product if you are under 16 years of age,
D Never operate this product when under the influence ofdrugs, alcohol or medications,
Read installation and operating instructions thoroughly.
Notice
Equipment Damage
D 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.
I. PARTS LIST
ITEM DESCRIPTION
PIN
OTY
1
2
3
4
5
6
7
8
9
RETAINING RING
#6 SCREW
CLUTCH CAP
WAVE SPRING
THRUST WASHER
THRUST ROLLER BEARING
BRAKE DISK ASSY
BRAKE PLATE
SCREW 4MM X 97.5MM
81210
70192
72508
66532
80846
80845
82041
82040
73803
1
6
NOTE 1: TORQUE #6 SCREWS TO 1.8 +/- 0.4 Nm (16+/- 4.0 in.lbs.)
WARN INDUSTRIES PAGE 2
81816AO
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of
Warn Industries Inc,

II. REQUIRED TOOLS
T15 Torx Screwdriver
Retaining ring pliers
Flat blade screwdriver
III. INSTALLATION
1. Refer to winch and mounting kit instructions to
remove winch from vehicle.
To maintain winch
end housing alignment, install 4mm screw
through drum support and tighten until threads
are flush with drum support, see Figure
1.
2. Place winch on a well lit flat surface and sup-
ported
on motor end.
3. Turn the Clutch Dial so that it is in the Freespool
position. Push
in on the red tab at either end of
the handle with a flat blade screwdriver (Figure
2). Lift and remove the handle from the Clutch
Dial.
4. Use external retaining ring pliers to expand re-
taining ring (Figure 3). Expand retaining ring
only enough to allow it to
be lifted from center
hub. Remove retaining ring and then lift Clutch
Dial from Clutch Bar and Clutch Cap.
5. Turn the Clutch Bar so that the heads of the
Clutch Pins are
in the eyes of the bar key slots
(Figure 4). Lift the Clutch Bar vertically from the
Clutch Cap.
6. Use a T15 Torx screwdriver to remove the (6)
screws securing the Clutch Cap to the Gear
Housing (Figure 5). Lift the Clutch Cap from
the Gear Housing and Drive shaft. Discard the
clutch cap. Discard coil spring under clutch cap.
See Figure 6.
WARN INDUSTRIES PAGE 3
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 1
Figure 5
81816AO

BRAKE INSTALL
7. Rotate Stage 1 Sun Gear until it fully seats inside
of Stage 1 Carrier Set and is engaged with Drive
Shaft (Figure 7).
NOTE: A sealed version of the winch is
shown in Figures 7 through 12. Your winch
may not have o-rings shown in these images.
See WARN
part number 74925 for winch D-
ring kit.
9. Place brake retaining plate in hex bore of gear
housing (Figure 8).
10. Place Brake Disk Assembly over Drive Shaft and
slide it down until disk surface is resting
on Brake
Retaining Plate (Figure 9).
11 . Apply a small amount of high temperature grease
to the back of Brake Disk Assembly if there is
none
on disk (Figure 10).
WARN INDUSTRIES PAGE 4
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks
of Warn Industries Inc.
(Discard)
~<; "JJ
Figure 6
Figure 7
Figure 9
Figure 10
81816AO

12. Place Thrust Bearing on the back of Brake Disk
in the high temperature grease (Figure 9).
13. Place the Thrust Washer on the Thrust Bearing
(Figure 10). The roller clutch of the Brake Disk
Assembly should center the washer.
14. Place the Brake Spring
on the Thrust Washer
and center it
on the washer (Figure 11). Care
should be taken to assure that the brake spring
is centered adequately to fit with the clutch cap
in
the next step.
15. Align the new Clutch Cap with Clutch Pins, Drive
Shaft, Brake Spring and fastening holes. Place
the new Clutch Cap
on Gear housing making
sure that Brake Spring is in spring bore (Figures
14and 15).
16. Install (6) Torx head fasteners with T15 Screw-
driver. Tighten these fasteners
in a cross pattern
so that Clutch Cap is fastened down straight and
on center. Torque #6 fasteners to 16in.lb. (1.8
Nm).
17. Align the Clutch Bar with the Clutch Cap center
WARN INDUSTRIES
PAGES
©2009 Warn Industries, Inc.
WARN® and
th e WARN logo are trademarks of Warn Industries Inc.
Figure 11
Figure 12
Figure 13
Figure 14
81816AO

hub and Clutch Pins. Rotate the bar so that the
heads of the Clutch Pins are
in the eyes of the
bar key slots. Lower the Clutch Bar
on to the
Clutch Cap
so that the heads of the Clutch Pins
protrude through the slots. Rotate the Clutch Bar
so that the ends are at the bottom of the ramps
on Clutch Cap (Figure 16). The pins must move
freely in the Clutch Bar slots.
18 . Align bumps on Clutch Dial with matching fea-
tures
on Clutch Bar (Figure 17). Push the Clutch
Dial down over Clutch Cap center hub. Use re-
taining ring pliers to install retaining ring. Check
for proper installation by turning Clutch Dial to
Freespool position. Reinstall Clutch Dial if it
does not move freely.
19. Reinstall clutch handle.
20. Follow winch and mounting kit instructions to re-
install winch
on vehicle.
Figure 15
Figure 17
WARN INDUSTRIES PAGE 6 81816AO
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks
of Warn Industries Inc.

, . . ~,
A WARNING
READ THE VEHICLE'S OPERATOR MANUAL,
WINCH OPERATOR MANUAL, AND
ALL
WARNING LABELS PRIOR TO OPERATION OF
ATV AND WINCH.
., "''' . 1"
A WARNING . ..~.
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 OPERATOR INJURY OR DEATH.
DOUBLE CHECK THAT
ALL BOLTS ARE
SECURELY TIGHTENED PRIOR TO USE.
IV. MAINTENANCE/CARE
1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hard-
ware 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.
PERFORM REGULAR INSPECTIONS ON THE WINCH, WINCH MOUNT, AND RELATED HARDWARE.
NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS. FAILURE
TO FOLLOW THIS
WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.
WARN INDUSTRIES PAGE 7 81816AO
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks
of Warn Industries Inc.