Warn 89535 User manual

©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 1 89548A0
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
FRONT WINCH MOUNTING KIT
Part Number: 89535
Application: 2012 Can Am Renegade 800R
GENERAL SAFETY PRECAUTIONS
WARNING
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.
Impact and Moving Parts Entanglement Hazard
FAILURETO OBSERVETHESE INSTRUCTIONS COULD LEADTO SEVERE INJURY OR DEATH
• 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:
• 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 ever operate thisWARN product with damaged or missing parts.
Read installation and operating instructions thoroughly.

©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 2 89548A0
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.
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.
NOTES
BEFORE YOU BEGIN
TABLE OF CONTENTS
Parts List.........................................................................................................................................page 3
Tools Required.............................................................................................................................page 3
Torque Specications................................................................................................................page 3
Installation ............................................................................................................................. page 4-11
Maintenance/Care................................................................................................................... page 11

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PARTS LIST
Ref. Qty Part Number
A1 2 M8 Lock Washer
A2 2 5/16 Washer
A3 4 M8-1.25 Flange Hex Nut
A4 2 M8-1.25 x 25mm Flat Hex Head Capscrew
A5 2 Spacer
A6 4 M8X1.25 x 30 Flange Hex Head Capscrew
A7 4 M8x1.25 x 25 Flange Hex Head Capscrew (not shown)
A8 2 M8x1.25 x 20 Flange Hex Head Capscrew (not shown)
TOOLS REQUIRED
- 13mm, 10mm, 17mm socket Wrench
- 13mm, 10mm, 17mm Standard Wrench
- Torx Set
- Short extensions for all socket wrenches
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
1/4 6mm 8 lb. ft. (10.8 N-m)
5/16 8mm 17 lb. ft. (23.0 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)
Ref. Qty Part Number
B1 1 Contactor Plate
B2 1 Upper Bracket
B3 1 Winch Mount
B4 2 Gusset
A6
A5
A4
A3
A2
A1
B3
B2
B4
A6
B1

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INSTALLATION INSTRUCTIONS
1. Remove the plastic skid plate by removing the outside bottom and inside top bolts.
2. Uninstall the upper bracket by removing the three long bolts and short bolt shown.

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3. Uninstall the aluminum bumper by removing the two lower mount bolts and the front two bolts.
4. Remove the top two bolts to uninstall the top bumper bracket.
5. Mount the winch using four M8 x 1.25 x 25mm bolts (A7) supplied in this kit and lock washers supplied in winch kit.
6. Pull the winch rope through the front window of the winch mount.
INSTALLATION INSTRUCTIONS
Winch Rope
(A7)

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7. Install the blue and yellow contactor wires as shown.
Note: The blue wire should be positioned towards the back of the winch and the yellow towards the front.
8. Install the gussets loosely using two M8 x 1.25 x 30mm bolts (A6) and two locking nuts (A3) on top and two countersunk bolts (A4)
with two locking nuts (A3) on the bottom. After all bolts are in place, tighten all hardware to specications on page 3.
NOTE: Review exploded view on page 3 for gusset orientation.
9. Position winch mount assembly on vehicle.
INSTALLATION INSTRUCTIONS
Yellow
Blue

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10. Secure the winch mount assembly using the two factory bolts and two lock washers (A1) and washers (A2) supplied in this kit.
Note: Install loosely at this time to allow for adjustment. NOTE: Review exploded view on page 3.
11. Re-attach the front of the plastic skid plate to aluminum bumper the front two bolts only at this time, allowing the bottom of the
skid plate to remain loose.
12. Slide the bumper over the front fairlead tabs.
INSTALLATION INSTRUCTIONS
Factory bolt w/ A1
and A2

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13. Attach the upper part of the bumper loosely by installing the remaining two M8-1.25 x 30 long bolts (A6) and spacers (A5) with the
factory nuts.
14. Loosely install the lower factory bumper mounting bolts with nuts.
15. Tightenall bumper hardware now.
16. Install the bottom skid plate bolts to nish mounting the plastic skid plate.
INSTALLATION INSTRUCTIONS

©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 9 89548A0
17. Loosen the top roller of the fairlead to allow the wire/synthetic rope through.
18. Tighten the top roller down after the loop is through.
19. Mount the fairlead to the front tabs using the fairlead hardware given.
INSTALLATION INSTRUCTIONS

©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks ofWarn Industries Inc. 10 89548A0
20. Mount the upper bracket using the manufacturer’s hardware.
21. Secure the lower tab and the winch by installing the remaining front two M8 bolts, found in winch kit.
22. Tighten all winch mounting, bumper and skid plate hardware to torque specications on page 3.
Contactor installation and wiring
1. Mount the contactor to the contactor plate (B1) and attach the plate mounting location using the two M8 bolts (A8) provided.
Attach the red and black wires to the coordinating color marked contactor terminal, using hardware with contactor.
INSTALLATION INSTRUCTIONS
Contactor plate mounting
location Contactor plate
Contactor

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2. Route the blue and yellow wires from the winch to the color coded terminals on the contactor and connect using hardware in
winch kit.
3. Remove the seat and route the red and black wires to the battery under the seat as shown.
INSTALLATION INSTRUCTIONS
MAINTENANCE / CARE
• Inspect all metal parts on the plow, plow mount, and related hardware prior to each use. Replace all parts that appears rusted or
deformed.
• 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 must be replaced.
• 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.