Warn 87355 User manual

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 88126A0
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 Sales/Customer Service: 1-503-722-3008
International Fax: [phone]
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number: 87355
Application: 2011 + Polaris Sportsman 400, 500, 800
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 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.
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.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 88126A0
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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.
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.
TABLE OF CONTENTS
Tools Required.......................................................................................................page 2
Torque Specications............................................................................................page 2
Parts List................................................................................................................page 3
Installation......................................................................................................... page 4-5
Maintenance/Care................................................................................................page 5
TOOLS REQUIRED
- 13mm Wrench
- 13mm Socket
- Socket Wrench
TORQUE SPECIFICATIONS
1/4 (6mm) 8 lb. ft. (10.8 N-m)
5/16 (8mm) 17 lb. ft. (12.5 N-m)
3/8 (10mm) 30 lb. ft. (40.7 N-m)
7/16 (11mm) 50 lb. ft. (67.8 N-m)
1/2 (13mm) 75 lb. ft. (101.7 N-m)

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 88126A0
PARTS LIST
Description Qty Ref.
Plow Mount 1 A1
Bracket RH 1 A2
Bracket LH 1 A3
Large Washers 1 A4
J Bolt Bracket 1 A5
M8 Hex Head Bolts 6 B1
Flat Washers 10 B2
Lock Nuts 4 B3
1/4-20 J-Bolt 2 C1
3/8-16 x 1 Hex Bolt 2 C2
3/8” Flat Washer 2 C3
3/8-16 Lock Nut 2 C4
1/4” Flat Washer 2 C5
1/4-20 Lock Nut 2 C6
C1
C3
C4
A5
C5
C6
C2
A2
A1
B1
A4 B3
B2
A3

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 88126A0
INSTALLATION INSTRUCTIONS
1. In step one locate the welded puck on your plow mount.
Insert the puck into the hole as shown in gure 1. Take one
of the hex head bolts and a at washer and insert it through
the the hole with the puck you inserted through the frame.
2. On the top side of the skid plate place the large black
washer over the bolt along with a at washer and lock nut.
Do not tighten yet but you can take some of the slack out of
the threads. See gure 2.
3. Locate and position the RH bracket a shown in gure three
over the top of the frame. Attach to the plow mount using
two hex head bolts four at washers and two lock nuts. Do
not tighten at this time. See gure 3.
Figure 1
Figure 2
Figure 3
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always remove jewelry and wear eye protection.
Read installation and operating instructions thoroughly.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 88126A0
INSTALLATION INSTRUCTIONS
4. Place the left hand bracket over the frame and line the
holes up with the plow mount. Place the three remaining
hex head bolts along with three at washers up through the
three holes. Then put three at washers along with the lock
nuts on the bolts. See gure 4
5. Tighten the bolt with the large black washer rst. Then you
can tighten the rest of the fasteners at this time. Try to
tighten the rest of the fasteners evenly, and not so much
that you distort the mount to much. See gure 5.
Figure 4 - Mark Plow Mount Slots
Figure 5 - Remove Plastic Skid Plate
MAINTENANCE / CARE
• Inspectallmetalpartsontheplow,plowmount,andrelatedhardware.Replaceallpartsthatappear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.
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.