Warn 70737 User manual

WARN INDUSTRIES PAGE 1 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number: 70737
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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ysys
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.
NeNe
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er lean over battery while making connections.
NeNe
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ver rer r
er rer r
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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.
NeNe
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er operate the vehicle on slopes greater than 10 degrees with the plow installed.
NeNe
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verer
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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.
Ne
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verer
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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.
Applications: 2007+ Suzuki King Quad 450; 2009+ Suzuki King Quad 500;
2005+ Suzuki King Quad 700; 2008+ Suzuki King Quad 750

WARN INDUSTRIES PAGE 2 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
III. TOOLS REQUIRED
- Ratchet
- 9/16” Wrench
- 9/16” Socket
- 1/2” Socket
- 7/16” Socket
-10mm Socket
-Drill & 11/32” Drill Bit
I. TABLE OF CONTENTS
Parts List page 2
Tools Required page 2
Torque Specifications page 3
Installation page 3-5
Tips/Troubleshooting page 6
Maintenance/Care page 6
II. PARTS LIST
Part Number Qty Description
69556 1 Plow Mount
62845 1 J-Bolt Bracket
69552 1 Mounting Hardware Kit
Caution
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Moving Pving P
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arts Entanglement Hazardts Entanglement Hazard
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ts Entanglement Hazard
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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
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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.

WARN INDUSTRIES PAGE 3 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 1
Figure 2
V. INSTALLATION
1. Install the plow mount using the fastener configura
tions as shown in Figure 1.
A. 3/8” Bolt, 3/8 Nylock Nut
B. J-Bolt, 1/4” Nut
C. 5/16” x 2.0” U-bolt, 5/16” Nylock Nut
2. To install the plow mount to the underside of the
vehicle, remove the factory skid plate. This will
require the use of a 10mm socket, as shown in Figure
2.
3. Once the skid plate is removed. Use the plow mount
as a template for holes to be drilled, as shown in figure
3.
Figure 3
Ax1
Bx2
Cx4
Skid Plate
Remove 6 Bolts
IV. FASTENER TORQUE SPECIFICATIONS
1/4 & M6 8 lb. ft. (10.8 N-m)
3/8 & M10 30 lb. ft. (40.7 N-m)
7/16 50 lb. ft. (67.8 N-m)
1/2 75 lb. ft. (101.7 N-m)
5/16 U-Bolt 11 lb. ft. (14.9 N-m)

WARN INDUSTRIES PAGE 4 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 4
Figure 5
INSTALLATION CONT.
4. Place the plow mount 6” in front of the circular hole in
the skid plate, as shown in figure 4.
5. Place the edge of the plow mount 3/16” away from the
edge of the skid plate. The opposing edge of the plow
mount will hang partially over the edge of the skid
plate. Make sure the plow mount is perpendicular to
the skid plate. Mark all hole locations on the skid
plate by scribing the plastic with a sharp object. Using
a 11/32” drill bit, drill through the skid plate, as shown
in figure 5.
6. Reinstall the skid plate with the six fasteners removed
in step 2. Install the plow mount with the provided
fasteners by placing the U-Bolts over the frame with
the threaded ends protruding through the plow mount.
Attach the 5/16” washers and nuts as shown in Figure
6. It is important that all fasteners are loosely installed
until final assembly. It may be necessary to slot the
hole locations on the skid plate for the U-Bolts to line
up with the skid plate. The picture shown is from the
rear of the bike looking forward.
Figure 6
7. Tighten all fasteners securely. Torque 5/16” bolts to
11 ft. lbs.
Mark all hole
locations and scribe
3/16”
Front of bike

WARN INDUSTRIES PAGE 5 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION CONT.
9. If using a winch to operate the plow, install the J-Bolt
bracket (62845) to the cross-member of the plow.
Note: If using a winch to operate your plow, proceed to
step 10. If using an electric actuator, or manual lift to
operate your plow, please refer to the instructions that
came with the manual lift kit.
10. Run the winch cable through the roller fairlead and
down to the plow. Attach through the end of the
winch cable around the end of the J-Bolt. Slide the
threaded end of the J-Bolt (C) through the round holes
in the bracket. The open end of the J-Bolt will fit into
one of the slotted holes.
Note: If you have a hook on the end of your winch
cable, simply move the hook out of the way when
attaching the cable to the J-Bolt.
11. Attach the 1/4” nut and washer to the end of the J-
Bolt. The J-Bolt should be tightened until the open
end drops down into the slot. Do not over tighten the
J-Bolt as this may pinch and damage the cable. The
completed assembly will look as shown in Figure 8.
Figure 7
Figure 8
Figure 9
8. If you haven’t already done so, assemble the plow per
the instructions included in the plow kit. Attach the
plow to the mount using the pins provided in the plow
kit.
Plow installation with a winch is now com-
plete. The assembled product should look like
Figure 9. Skip the rest of this section and
move to the next section titled “Maintenance/
Care”.

WARN INDUSTRIES PAGE 6 70736A3
©2007 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
VII. TROUBLE SHOOTING
VI. 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.
Trouble Inspection Diagnosis Action
A. Check that the
side slots in
skidpan align
with the hole
and nut in the
chassis.
Difficulty
getting bolts to
line up with
holes in
chassis.
1. Make sure the
skidpan slots aligns
with the hole when
the mount is not
compressed
against it.
1. Adjust and move the skidpan
while compressing the plow
mount against it until the
skidpan slots align with the
hole.
2. Make sure the
skidpan slots align
with the hole when
the U-bolts are put
throughthe
skidpan.
2. Increase the diameter or slot
the holes drilled through the
skidpan until the skidpan
slots align with the holes.
The electric
actuator cable
will not rotate
within the
termination
bracket.
A. Check the
terminationof
the actuator
cable.
1. Make sure the
cable is in the slot
of the termination
bracket, the
cylindrical pin is
attached to the
cable, and the
terminationbracket
is attached such
that it leans toward
the plow blade.
1. Mount the bracket to the
plow crossmember on the
plow blade side angling
toward the blade. Slide the
end of the actuator cable
throughthe termination
bracket slot. Slide the
cylindrical pin over the end of
the cable and terminate with
a 1/4” nut (D). The com-
pleted assembly should look
like Figure 12.
A. Check the
alignment of the
plow mount
holes in relation
to the plow
holes.
Difficulty
gettingplow
pins through
the plow and
plow mount.
1. Make sure the plow
and vehicle are
both on a flat non-
sloping surface.
1. Move the plow and vehicle to
a flat non-sloping surface.
2. Make sure the plow
holes align per-
fectly with the plow
mount holes.
2. Place a smaller diameter rod
(such as a drill bit) through
the holes and align the two.
Once the two are aligned,
hold the plow in place and
put the plow pin through the
two holes.