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©2019 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

103450A0

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

BUMPER WINCH MOUNT KIT

Part Number: 103420

Application: 2019 Polaris RZR Turbo S

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 103420

Page 1: ...delectricalterminals Alwaysinstallterminalbootsasdirectedininstallationinstructions Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace Alwaysinsurecomponentswillremainsecureduringinstallationandoperation Alwaystightenallnutsandboltssecurely pertheinstallationinstructions Alwaysperformregularinspectionsandmaintenanceontheplowmechanism fasteners cableandrelatedhardware Alwaysreplaceallw...

Page 2: ...nstructions could lead to minor or moderate injury AlwaystaketimetofullyreadandunderstandtheinstallationandOperationsGuideincludedwiththisproduct Neveroperatethisproductifyouareunder16yearsofage Neveroperatethisproductwhenundertheinfluenceofdrugs alcoholormedications Read installation and operating instructions thoroughly N O T E S B E F O R E Y O U B E G I N T A B L E O F C O N T E N T S Tools Re...

Page 3: ...que 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 5 10 7 16 48 66 M8 18 25 1 2 74 100 M10 37 50 9 16 106 144 5 8 148 200 3 4 269 364 ITEM PN DESCRIPTION QTY B1 92506 M10 X 1 25 NYLOC NUT 2 B2 93104 M8 1 25 x 25 FLANGE BOLT 4 B3 ...

Page 4: ... so the plate will not fall behind the bottom of the skid pan If nut plate should fall see step 4 Retain hardware for later reuse 2 Remove grill by depressing tabs and pull towards you 3 Remove the torx head screws for the lower plastic and unsnap the top of the plastic from the vehicle 4 If nut plate should fall in step one remove the two torx head screws shown Pull outward on plastic and retriev...

Page 5: ... Do not tighten completely to allow for adjustment 6 Attach the upper bumper support A1 using the M12 hardware B3 B4 NOTE Slide the bolt up through the frame and attach the nut topside Do not tighten completely to allow for adjustment 5 Install one M10 bolt B6 through the outer side of the upper bumper support metal flange and lower bumper support mounting holes Secure with a M10 nut B1 6 Repeat f...

Page 6: ...Reinstall grille 15 Install fairlead to fairlead bracket plate using hardware in your winch kit 16 Place fairlead bracket plate assembly over the holes in the bumper mount NOTE Install the winch electrical cables to the winch prior to installation 17 Place the winch on top of the fairlead plate 18 Mount the winch using the four M8 bolts B2 included in this kit TIP Use a drive socket with long exte...

Page 7: ...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 19 Install three M8 flange bolts B7 through the bottom of the bumper and the lower bracket Secure with M8 locking nuts B5 Do not tighten completely 20 Tighten winch mounting bolts ...

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