Warn 70558 User manual

WARN INDUSTRIES PAGE1 70557A2
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number: 70558
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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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.
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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.
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er operate the vehicle on slopes greater than 10 degrees with the plow installed.
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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.
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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 emphasize
general information worthy of special attention.
Application: 2006+ Kawasaki 750 Brute Force 4x4i
2006+ Kawasaki 650 Brute Force 4x4i

WARN INDUSTRIES PAGE2 70557A2
I. TABLE OF CONTENTS
Parts List page 2
Tools Required page 2
Installation page 3-5
Winch and Lowering Plow Instructions page 6-7
Maintenance/Care page 8
II. PARTS LIST
Part Number Qty Description
A1 1 Plow Mount
B1 4 5/16-18 x 1 3/8” x 2” u-bolt
B2 8 5/16” Flat Washer
B3 8 5/16-18 Lock Nut
Caution
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Moving Pving P
ving Pving P
ving Parar
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arts Entanglement Hazardts Entanglement Hazard
ts Entanglement Hazardts Entanglement Hazard
ts Entanglement Hazard
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ailure tailure t
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ve these instructions could lead te these instructions could lead t
e these instructions could lead te these instructions could lead t
e these instructions could lead to minor or moderato minor or moderat
o minor or moderato minor or moderat
o minor or moderate injure injur
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.
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
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.
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. TOOLS REQUIRED
- Ratchet
- 10mm Socket
- 1/2” Socket
- 3/8” Drill
Note:
Please refer to the Winch and Lowering Plow Instructions, p 5-6, if you plan to lower your plow using a
winch.
B1
A1
B3
B2

WARN INDUSTRIES PAGE3 70557A2
Figure 1
Figure 2
IV. INSTALLATION
1. Remove the four skid plate bolts, Figure 1.
Loosen the front two skid plate bolts, and remove
the skid plate from the vehicle.
2. Place the plow mount (A1) on the skid plate,
Figure 2.
3. Center the plow mount (A1) and place it as
shown, Figure 3. Mark the four hole locations
from the plow mount onto the skid plate, Figure 2.
Figure 3
Remove
Skid Plate
Skid Plate
A1
A1
Holes

WARN INDUSTRIES PAGE4 70557A2
Figure 4
Figure 5
INSTALLATION CONT.
Holes
Gusset
B1
Figure 6
A1
B2 B3
4. Use the 3/8” drill to make the four holes in the skid
plate, Figure 4.
5. Reattach the skid plate to the vehicle. Place the
supplied u-bolts (B1) around the tubes and through
the drilled holes in the skid plate, Figure 5.
6. Fasten the plow mount to the vehicle with the u-
bolts, flat washers (B2) and lock nuts (B3), Figure 6.
Align the plow mount with the bike. Trim the skid
plate holes if necessary. Tighten the u-bolts to 10lb
ft (14 N-m).

WARN INDUSTRIES PAGE5 70557A2
7. Remove the aluminum skid plate from the
vehicle.
8. Place the plow mount on the skid plate with the
bent portion of the mount facing the back of the
skid plate as shown in figure 7.
9. Center the mount side-to-side on the skid plate,
and measure the distance from the back tube
notches to the mount as shown in figures 8-9.
10. Place the mount 21.8" from the tube notches.
Mark the plow mount holes on the skid plate.
11. Drill the marked holes in the skid plate using a 3/
8" diameter drill.
12. Mount the skid plate on the vehicle as directed in
the skid plate installation instructions.
13. Refer to steps 5-6 for plow mount attachment
with the exception that the flat washers will not be
used on the rear u-bolts.
ADDITIONAL INSTALLATION INSTRUCTIONS FOR THE KAWASAKI
ACCESSORY ALUMINUM SKID PLATE:
Figure 7
Figure 8
Figure 9

WARN INDUSTRIES PAGE6 70557A2
B. Tools Required
• Ratchet
• Sockets: 7/16”, 9/16”
• Wrenches: 9/16”
A. Parts List
Ref Part # Description Qty
A1 62845 J-bolt Bracket 1
B1 35391 1/4” dia J-bolt 2
B2 1320 1/4” dia flat washer 2
B3 6725 1/4” dia nylock nut 2
C1 1827 3/8” dia x 1” long bolt 1
C2 11524 3/8” flat washer 1
C3 6779 3/8” nylock nut 1
C1
C2
B1
B2
B3
C3
A1
WINCH AND LOWERING PLOW INSTRUCTIONS:

WARN INDUSTRIES PAGE7 70557A2
C. Installation
1. Attach the J-bolt bracket (A1) to the center hole in
the plow crossmember using a 3/8” dia x 1” long
bolt (C1) as shown in figure 1. The bracket
should be mounted on the blade side of the
crossmember with the side flanges parallel to the
ground. Terminate the bolt with a 3/8” dia flat
washer (C2) and 3/8” dia nylock nut (C3). Tighten
the bolt and nut to a recommended torque of 20
ft-lb (28 N-m).
2. Run the winch cable over the roller fairlead and
down to the J-bolt bracket (A1). Using a 1/4” dia
J-bolt (B1), hook the loop on the end of the winch
cable and slide the threaded end of the J-bolt
through the round holes in the J-bolt bracket. The
hook end of the J-bolt should slide into the slotted
hole in the J-bolt bracket. Terminate the end of
the J-bolt with a 1/4” dia flat washer (B2) and 1/4”
dia nylock nut (B3). Tighten the nut until the
winch cable is snug inside the J-bolt as shown in
figure 2.
NOTE: Do not remove the winch hook installed on the
end of the winch cable, simply slide it out of
the way.
Figure 1 Installed J-bolt Bracket
C1, C2,
& C3 A1
B1, B2,
& B3
Cable End
Figure 2 J-bolt and Winch Cable
Installation is now complete. Proceed to the next
section entitle Maintenance/Care.
CAUTION
The purpose of the J-bolt is to break the
connection between the plow and ATV when
the plow is subjected to high forces that could
damage the plow or vehicle. The plow will
drop instantly if the J-bolt breaks, so be sure
there are no bystanders when operating the
plow. Instances when the J-bolt might break
are:
•If the plow is raised too high and stalls.
•If the operator is trying to lift too much
material with the plow blade.
In general, do not raise the top of the plow
blade above the headlights of the vehicle. If
the plow stalls, stop the winch immediately and
lower the plow. After pushing material with the
plow, backup the ATV prior to raising it. If the
J-bolt breaks, replace it with the spare
hardware found in this kit. Read the Plow
Operators Guide for more information.

WARN INDUSTRIES PAGE8 70557A2
V. 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.