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©2016 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

100956A1

WARN INDUSTRIES, INC.

 12900 S.E. Capps Road,

Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000

Customer Service:

 1-800-543-9276

Dealer Locator Service:

 1-800-910-1122

International Fax:

 1-503-722-3005

INSTALLATION INSTRUCTIONS

WINCH MOUNT KIT

Part Number: 100878

Application: Polaris Sportsman XP, SP, X2 Touring

G E N E R A L   S A F E T Y   P R E C A U T I O N S

  

 

W A R N I N G

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to severe injury or death

•  Always 

take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations.

•  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:

  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

 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.

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 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.

Summary of Contents for 100878

Page 1: ...iringandelectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysrepl...

Page 2: ...7 Maintenance Care page 7 T O O L S R E Q U I R E D Standard sockets Metric sockets Socket extension Ratchet T O R Q U E S P E C I F I C A T I O N S Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions FASTENERSIZE FASTENERTORQUE FASTENERSIZE FASTENERTORQUE lb ft N m lb ft N m 1 4 8 11 M4 2 3 5 16 17 23 M5 4 5 6 3 8 30 40 M6 7...

Page 3: ...P A R T S L I S T ID Part No Description Qty B1 2002 5 16 NUT LOCKING 4 B2 1324 5 16 FLAT WASHER 4 B3 93105 M8 FLAT WASHER 4 B4 1402 5 16 LOCK WASHER 4 B5 7355 5 16 CARRIAGE BOLT 4 B6 22508 M8 HEX HEAD BOLT 4 ID Part No Description Qty A1 100896 WINCH MOUNT BRACKET 1 A2 100898 FAIRLEAD BRACKET 1 ...

Page 4: ...ead screws 2 With front grill removed it may be necessary to remove some of the surface weld which may interfere with placing the winch mount into place 3 Remove just enough weld that it is even with the mounting flange from both sides 4 Before installing the winch to the mount insert the upper and lower carriage bolts B5 Refer to exploded view on page 3 Figure 1 Figure 2 Figure 3 Figure 4 Upper B...

Page 5: ...re that came with your winch 6 Attach the fairlead to fairlead bracket 7 Secure fairlead bracket to winch mount 8 Tighten all hardware refer to page 2 for specifications 9 The winch mount winch fairlead bracket and fairlead are now ready to install as one unit I N S T A L L A T I O N I N S T R U C T I O N S Figure 5 Figure 6 Figure 7 Figure 8 ...

Page 6: ...c 6 100956A1 10 Slide the assembled winch unit into position same area where you removed the welds 11 Secure with remaining fasteners provided and tighten NOTE For 570 Models You will need to reverse the direction of bolts to allow for clearance Figure 11 Figure 9 Figure 10 Figure 11 ...

Page 7: ...rn front plow mount you will need further trimming of the plastic See the front plow mounting instruction for this procedure 15 Your installation is now complete Figure 13 M A I N T E N A N C E C A R E 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 rel...

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