Warn 102770 User manual

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 1 64673A2
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
ATV PLOW ACCESSORY
Part Number: 102770
Application: 2003+ YAMAHA KODIAK 450/400
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 ensure 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.

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 2 64673A2
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
FAILURETO OBSERVETHESE INSTRUCTIONS COULD LEADTO 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
Parts List.........................................................................................................................................page 2
Torque Specications................................................................................................................page 2
Installation ................................................................................................................................page 3-4
Maintenance/Care......................................................................................................................page 4
TOOLS REQUIRED
- Rachet
- 7/16” Socket
- 7/16” Box Wrench
- 1/2” Socket or Box Wrench
- 9/16” Socket
- 9/16” Box Wrench
- Drill
- 3/8” Drill Bit
- Diagonal Cutter or Similar
- Permanent Marker or Similar
PARTS LIST
Ref PN Description Qty
A1 64224 Plow Mount 1
A2 64227 Tab 1
A3 62845 J-Bolt Bracket 1
B1 31804 1/4” dia-1” long Bolt 2
B2 35391 1/4” J-bolt 2
B3 1320 1/4”Washer 2
B4 6725 1/4” Nylock Nut 4
C1 60869 5/16” dia-1 3/8” wide U-bolt 4
C2 1324 5/16”Washer 8
C3 2002 5/16” Nylock Nut 8
D1 1827 3/8” dia-1” long Bolt 1
D2 6779 3/8” Nylock Nut 1
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

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 3 64673A2
1. Attach the Tab to the Plow Mount with two 1/4” dia-1” long
bolts, 1/4” washers, and 1/4” nylock nuts as shown in Figure
1. Align the tab edges to the plow edges before tightening.
The heads of the bolt should be on the tab side while the
washers and nuts on the underside of the plow mount.
2. Place the Plow Mount underneath the vehicle with the
chamfered edges facing the front of the ATV. Place the
Tab inside the rectangular opening of the skidplate. Jiggle
the plow mount to be sure the tab is in the opening, there
should be minimal movement. Be sure the plow mount is
aligned properly and not rotated to one side.
3. Using a permanent marker (or similar), mark inside each of
the eight open holes on the Plow Mount and onto the skid-
plate as shown in Figure 2 . Remove the plow mount from
the vehicle when nished. Do not remove the Tab.
4. With a drill and 3/8” bit, drill through the skidplate at each
marked location with the exception of the two outside ones.
Proceed slowly and drill only through the skidplate. Pay at-
tention not to drill or damage any other component on the
vehicle.
5. With diagonal shears (or similar) cut the sides of the skid-
plate removing the two outside marked locations.
6. Slide 5/6” dia-1 3/8” wide U-bolts over the vehicle frame and
through each set of holes for a total of four. Due to vehicle
design, the two center U-bolts can only be accessed on one
side of the vehicle.
7. Place the Plow Mount back underneath the vehicle. Slide the
ends of the U-bolts through the open holes on the mount.
The Tab should t back inside the rectangular opening in the
skidplate.
8. Attach 5/16” washers and 5/16” nylock nuts to the end of
each U-bolt. Tighten securely. The complete plow mount
should look like Figure 3.
9. Attach the plow to the Plow Mount using the clip pins found
in the plow blade kit.
INSTALLATION INSTRUCTIONS
WARNING
• BE SURETO DRILL THROUGH ONLYTHE SKIDPLATE. DRILLINGTHROUGH ANY COMPONENT ON
THE ATV OTHERTHAN THE SKIDPLATE CAN SEVERELY DAMAGE THEVEHICLE WHICH CAN LEAD
TO OPERATOR INJURY OR DEATH.
Figure 1
Figure 2
Figure 3

©2018 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 4 64673A2
INSTALLATION INSTRUCTIONS
10. The following steps describe the method for raising the plow
with a winch. If you are using an electric actuator or manual
lift, please following the instructions included in those kits..
11. Attach the J-Bolt Bracket to the plow crossmember using a
3/8” dia-1” long Bolt, and 3/8” Nylock Nut as shown in
Figure 4. The bracket should be installed on the plow blade
side of the crossmember. Attach the 3/8” bolt such that the
head of the bolt is inside the bracket and the threaded end
points toward the ATV.
12. Run the winch cable down over the roller fairlead and to the
J-Bolt Bracket. Slide the loop end of the winch cable over the
hook of the J-bolt. If a winch hook is attached to the loop
end of the cable, position it out of the way or remove it.
13. Slide a J-Bolt down through the round hole in the J-Bolt
Bracket and terminate with 1/4” washer and 1/4” nylock nut
as shown in Figure 5. The end of the hook should be sitting
in the slotted hole in the bracket.
Figure 4
WARNING
• BE SURETHERE ARE NO BYSTANDERS WHENYOU RAISE AND LOWER THE PLOW.
• DO NOT RAISETHE TOP OFTHE PLOW ABOVETHE HEADLIGHTS OFTHE ATV AS IT IS NOT ONLY
UNNECESSARY, BUT POTENTIALLY DAMAGING TOTHEVEHICLE AND PLOW.
• IFYOU NOTICE DEFORMATION OF THE J-BOLT, ORTHE J-BOLT IS BROKEN, REPLACE IMMEDIATELY
WITHTHE SPARE J-BOLT INCLUDED IN THE KIT.
WARNING
• DRIVE SLOWLY OVER BUMPY AND ROUGHTERRAIN. DRIVING AT SPEEDS THAT CAUSETHE PLOW
TO BOUNCE WHILE INTHE UP POSITION CAN CAUSETHE WINCHTO BACK-DRIVE CAUSINGTHE
PLOWTO WORK ITS WAY DOWN.THIS MAY RESULT INTHE PLOW IMPACTING A STATIONARY
OBJECT AND CAUSE DAMAGETO THEVEHICLE AND OPERATO R INJURY OR DEATH.
• DRIVE AT SPEEDS SUCH THAT THE PLOW DOES NOT BOUNCE AND BE AWARE OF THE PLOW
POSITIONWHILE DRIVING AT ALL TIMES.
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 5