Warn 84354 User manual

WARN INDUSTRIES PAGE 1 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
PART NUMBER: 84354
APPLICATION: 2002 + ARCTIC CAT 400-1000cc
WARNING
 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 insure 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 this WARN 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.
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 INSTRUC-
TIONS 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 recom-
mendations. 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.

WARN INDUSTRIES PAGE 2 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. TABLE OF CONTENTS
Tools Required ...............................................page 2
Torque Specications .....................................page 2
Parts List ........................................................page 3
Installation ...................................................page 4-6
Maintenance/Care ......................................... page 7
CAUTION
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.
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.
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.
IV. TORQUE SPECIFICATIONS
1/4 8 lb. ft. (10.8 N-m)
5/16 17 lb. ft. (12.5 N-m)
3/8/ 10mm 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)
III. TOOLS REQUIRED
- 3/8” Rachet, 3 1/2” Extension
- Sockets: 10mm, 13mm, 17mm, Deep 1/2”
- T30 Torx Head
- Drill and 3/8” Drill Bit

WARN INDUSTRIES PAGE 3 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
V. PARTS LIST
 Ref Description Qty
A1 Plow Mount 1
A2 RH Locate Bracket 1
A3 LH Locate Bracket 1
A4 Plow Jogged RH 1
A5 Plow Jogged LH 1
B1 Plow Retaining Pin 2
B2 5/16 x 1 3/8 U-Bolt 2
B3 5/16 x 1 1/2 U-Bolt 2
B4 5/16 Flat Washers 8
B5 5/16 Lock Nut 8
B6 3/8 Flat Washer 2
B7 M10-1.25 x 30 mm Hex Bolt 2
B8 1/4-20 Hex Head Bolt 4
B9 1/4-20 Flat Washer 8
B10 1/4-20 Lock Nut 4
B11 Nut Clip 2

WARN INDUSTRIES PAGE 4 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 1
Figure 2
Figure 3
VI. INSTALLATION
1. Remove the plastic front skid plate (Figure 1).
Use a T30 Torx head to remove the four bolts se-
curing the front skid plate to the front bumper.
Note: Removing the bottom two T30 bolts
will cause the plastic belly skid plate to hang
freely from the front. Leave hanging until in-
structed to drill holes in the end of this docu-
ment.
2. Remove the front bumper. Use a 10mm socket
to remove the upper two bolts securing the front
bumper to the frame, and a 13mm socket to re-
move the two bolts securing the bumper to the
lower frame tube. (Figure 2)
3. Attach the LH and RH locating bracket to the
plow mount. Use the supplied 1/4-20 hex head
bolts, washers and lock nuts as shown in Figure
3. Tighten the nuts just enough to take the slack
out of the bolts but allowing the brackets to slide.
See Figure 3.
CAUTION
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor or
moderate injury.
 Once the bumper is freed from the mount it can fall from
the vehicle. To prevent personal injury and damage to the
bumper/vehicle, remove the top two bolts but only remove
one of the bottom bolts. Hold the bumper with one hand then
remove the last bottom bolt.
Read installation and operating instructions thoroughly.

WARN INDUSTRIES PAGE 5 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION CONT.
4. Place the plow mount over the bottom frame
tube. Ensure the plastic belly skid plate is be-
tween the mount and the frame.
Install the two M10x 1.25 bolts through the cen-
tral holes and into the bottom frame tube. Do
not tighten, this is for positioning only. See
Figure 4.
5. Place two 5/16” x 1 3/8” U-bolts around the two
upright tubes and through the slotted holes in the
back of the face of the plow mount. Secure with
(4) 5/16” Flat washers and (4) 5/16” Nylock Nuts.
Tighten the U-Bolt nuts just enough to take the
slack out of the bolts but do not tighten. As you
will need to slide the mount upward into position
for the next step. See Figure 5.
6. Drill two holes into the plastic belly skid plate
where the inner/lower slotted holes are located
on the bottom tab of the plow mount. Place
two 5/16” x 1 1/2” U-bolts around the two bottom
frame tubes and through the slotted holes on the
bottom tab of the plow mount. Secure with (4)
5/16” Flat Washers and (4) 5/16” Nylock Nuts.
Do not tighten. (Figure 5)
7. Making sure the mount in centered on the ve-
hicle, tighten the two upper U-Bolts. Tighten
each nut to the torque specied in the Table at
the beginning of this document. Back the previ-
ous installed M10 bolts out about half way. Make
sure that the LH and RH locating brackets still
slide after you tightened the upper u-bolts in the
previous step.
8. Tighten the two lower U-Bolts. Tighten each nut
to the torque specied in the table at the begin-
ning of this document.
9. Remove the two M10 X 1.25 bolts from the cen-
tral holes.
10. Install the front bumper. First, install the top
two bolts and loosely secure. Then bring the
smashed bottom ends in between the inner locat-
ing tabs of the plow mount. Thread the (2) M10
X 1.25 bolts through the tab, spacers, attened
bumper tube end, and into the bottom frame
tube. Tighten to the torque specied in the table
at the beginning of this document. Tighten the
1/4-2 hex head bolt that attach the inner locating
tabs at this time. See Figure 6.
Figure 5
Step 4
Step 5
Figure 4
Figure 6

WARN INDUSTRIES PAGE 6 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
11. There is some pre-trimming to your front skid
plate required before installation. See Figure
7. This can be achieved with a utility knife or
a heavy pair of scissors. Mark 3 1/2 inches up
from the bottom end of the skid plate and 1 1/2
inches down on the side and cut that material
away.
12. Reinstall your plastic using the factory fasteners.
Make sure that the threaded u-clips have been
installed lower part of the plow mount over the
mounting holes. See instruction exploded view
for location on page 3. Figure 8 shows plastic
reinstalled.
13. Finally install the plow mounting tabs to your
Plow Tube Assembly with the jogged ends to-
ward the center (narrowest conguration pos-
sible) shown in Figure 9. Install these loosely
on the plow with the fasteners provided with the
plow. Tighten the fasteners after the plow is as-
sembled and installed in the mount according to
the plow assembly instructions.
Figure 7
Figure 8
Figure 9

WARN INDUSTRIES PAGE 7 80551A2
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
VII. 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 im-
mediately.
• 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.