Warn 80335 User manual

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InstructionDisclaimer
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INSTALLATION INSTRUCTIONS
WINCH MOUNTING KIT
Part Number: 80335
Application: Polaris Ranger RZR
AWARNING
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
D
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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, fire or
personal injury.
Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips.
Flying chips can cause eye injury.
Always use extreme caution when cutting and trimming during fitting.
Always remove jewelry and wear eye protection.
Never lean over battery while making connections.
Never route electrical cables:
Across any sharp edges.
Through
or near moving parts.
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 and operation.
Always perform regular inspections and maintenance on the winch, winch mount and related hardware.
Never operate this WARN product with damaged or missing parts.
WARN INDUSTRIES
PAGEl
80343AO

D
ACaution
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.
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
Eauipment DamaQe
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. BEFORE YOU BEGIN
Before you begin disconnect the positive battery lead from the battery.
II. TABLE OF CONTENTS
Torque Specifications
Tools Required
Parts List
Installation
Maintenance/Care
page 2
page 2
page 3
page 4-6
page 7
..
III. TORQUE SPECIFICATIONS
1I4,6MM
5/ 16,8MM
3/8,IOMM
7116, liMM
II2, 12MM
81b. ft.
(l0.8 N-m)
17 lb. ft. (12.5 N-m)
30 lb. ft. (40.7 N-m)
50 lb.
ft. (67.8 N-m)
75 lb. ft. (IOU N-m)
II
I!
IV. TOOLS REQUIRED
- 7116, 12mm, Socket
-7/16, 12mm End Wrench
-FlatBlade screw driver
-Torx head drivers
WARN INDUSTRIES
PAGE2
80343AO
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v. PARTS LIST
No.
Part Number
QJ:r.
I 1320 4
2 1324 4
3 22105 4
4 22508 4
5 31209 2
6 71588 4
7 77008 I
8 77010
WARN INDUSTRIES PAGE3
Description
1/4 Flat Washer
5/
16 Flat Washer
1/4-20 Locking Hex Nut
M8 x
.1.25 x 25 MM Hex Bolt
U-Bolt
114-20 x 1 114 x I 1/4
M8 x 1.25 Hex Flanged Lock Nut
Winch Mounting Bracket
Fairlead Mounting Bracket
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VI. INSTALLATION
1. Remove front bumper assembly, make sure to
disconnect the head lamps before removing
the bumper. The bumper is attached with 6
torx
head screws and 4 plastic push tabs
attaching the
bumper to the front fenders.
2. After removing the front bumper place the
mounting plate into position see figure 2. At
this time also place the winch into position
along with the
mounting plate.
Figure 1
Figure 2
3.
Before attaching the mounting plate to the
frame the winch will have to be attached to
the
mounting plate. Once the winch has been
attached to the mounting plate tighten down
all four bolts to the recomended torque of 17
lb. ft.
Figure 3
80343AO
4.
Attach the mounting plate with the winch to
the frame
using 2 114-20 V-bolts, washers
and locking
hex nuts. Just finger tighten the
hex nuts
at this time. This will help hold the
mounting plate into position while attaching
the fairlead
bracket and the rest of the hard-
ware, see figure 3.
WARl'J INDUSTRIES
PAGE4

INSTALLATION CONT.
5. Place the fairlead bracket into position as
shown in figure
4. the fairlead bracket will fit
over top
of the flange on the winch mounting
bracket. Insert 2
of the 8mm hex bolts and
flat washers through both brackets and into
the frame on the atv. Finger tighten the 8mm
hex flange nuts at this time. It
is best to leave
every thing as loose as possible at this point
in the installation.
Figure 4
Figure S
6. Attach the lower flange of the fairlead
bracket, see figure
5. Use 8mm hex bolts,
flat washers and hex flange nuts.
Figure 6
7. Tighten all
of the fasteners at this point in the
installation use the recomended torque specs,
see figure 6 shows the brackets in the correct
location before the front bumper is placed
back into position.
WARN INDUSTRIES
PAGES
80343AO

INSTALLATION CONT.
8. Remove the cover that is located on the front
bumper, the cover
is attached with 4 torx
head screws. Place the
bumper back into
position and check for fit. Because
of the
variation in each vehicle
make sure that the
roller fairlead will fit into the opening
of the
front bumper.
9.
If the the roller fairIead contacts the front
bumper, spacing the fairIead out with a
washer between the fairlead and the bracket
or cutting away part of the plastic bumper
should alleviate the fit issue, see figure 7 and
8
10. Attach the roller fairlead to the fairIead
bracket, use the hardware that came with the
winch.
11. Replace the
bumper and tighten down all
fasteners.
AWARNING
READ THE VEHICLE'S OPERATOR MANUAL,
WINCH OPERATOR MAt'lUAL, AND ALL WARN-
ING LABELS
PRIOR TO OPERATION OF ATV
AND WINCH.
Figure 7
Figure 8
THE WINCH MOUNTING PLATE INSTALLATION IS NO'W COMPLETE.
• Wire winch according to instructions found in winch kit.
PROCEED TO SECTION TITLED "MAINTENANCE/CARE".
WARN INDUSTRIES PAGE 6 80343AO

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.
VII. 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.
A WARNING
PERFORM REGULAR INSPECTIONS ON THE WINCH , WINCH MOUNT, AND RELATED HARD-
WARE. 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 80343AO