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

106859A0

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 Sales/Customer Service: 1-503-722-3008
International Fax: 1-503-722-3005

INSTALLATION INSTRUCTIONS

Winch Mount Bumper

Part Number: 106822

Application:  2020 Polaris General

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.

  

 

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

 Know Your Winch.  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.

• 

Never

 work under vehicle before properly securing vehicle.

• 

Always

 use appropriate and adequate care in lifting components into place.

• 

Never

 work under vehicle before properly securing vehicle.

• 

Always

 use appropriate and adequate care in lifting components into place. 

• 

Never

 use a jack to support the vehicle.

• 

Always

 use jack stands in pairs to support the vehicle.

• 

Always

 use jacks or jack stands only on a hard, stable, and level surface.

• 

Never

 exceed the rated capacity of a jack or jack stands.

• 

Always

 verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle. 

• 

Never

 work under vehicle before properly securing vehicle.

• 

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.

• 

Always

 replace all worn or damaged parts before operating.

• 

Never

 operate this WARN product with damaged or missing parts. 

• 

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

 use extreme caution when cutting and trimming during fitting.

• 

Always

 wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury.

• 

Always

 remove jewelry and wear eye protection. 

• 

Never

 lean over battery while making connections.

• 

Never

 route electrical cables across any sharp edge, through or near moving parts, near parts that become hot.  

Read installation and operating instructions thoroughly.

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

Summary of Contents for 106822

Page 1: ...ur winch and its operations Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never use a jack to support the vehicle Always use jack stands in pairs to support the vehicle Always use ja...

Page 2: ...g Consult with the manufacturer of your tow bar system for the proper vehicle tow bar brackets Read installation and operating instructions thoroughly MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury Part edges may be sharp Always use proper posture lifting technique or get lifting assistance while handling and installing product Read in...

Page 3: ...0 M10 37 50 9 16 106 144 5 8 148 200 3 4 269 364 B4 P A R T S L I S T T O R Q U E S P E C I F I C A T I O N S Item PN Description Qty A1 106824 UPPER BUMPER MOUNT 1 A2 94890 SUPPORT MOUNTING BRACKET 1 A3 106826 LOWER BUMPER MOUNT 1 A4 106830 BUMPER SHELL 1 A5 28885 FAIRLEAD PLATE 1 Item PN Description Qty B1 83474 M8 LOCK WASHER 4 B2 93104 M8 X 25MM HEX HEAD BOLT 4 B3 71588 M8 LOCK NUT 8 B4 65970 ...

Page 4: ...ime b Remove the upper grille by depressing the two grille tabs c Remove the two bolts and nuts that hold the tube bum per to the vehicle TIP Place a 15mm wrench behind the grill to hold on to the nuts while using a ratchet and 15mm socket on the front side d Remove the lower two bumper bolts and nuts using a 15mm socket 2 After removing the bumper remove the nut plate Located behind the two lower...

Page 5: ... the exploded view on page 3 for part A2 a Position the bracket A2 behind the sheet metal flange just behind the plastic grill b Install two flange head 10mm bolts B6 through the bracket and sheet metal flange c NOTE The mounting holes vary in size The size of the mounting hole determines the size of the bolt for this step Install the two flange head bolt B8 OR B6 up through the frame and through ...

Page 6: ...olts B4 and lock nuts B3 6 Attach the upper bumper mount by placing over the previously installed M10 bolts 7 Thread the supplied flange lock nuts B5 on but do not tighten yet 8 Continue installing using two M12 hex head bolts B8 lock nuts B7 and the two lower M8 hex head bolts B4 and lock nuts B5 Once all the hardware is installed tighten ALL hardware at this time Figure 9 Figure 8 A1 B5 B4 B3 B8...

Page 7: ...tion 10 With plastic on a flat and stable surface carefully use a pneumatic reciprocating saw or similar to cut the plastic where marked NOTE It can be helpful to cut a smaller portion out for the first cut and fine tune the cut after test fitting The edges can be smoothed with a file or sanding disc 11 Reinstall the front center plastic to the vehicle using the four push pull pin fasteners 12 Sli...

Page 8: ...nting holes 16 Place the winch on top of the fairlead plate aligning mounting feet with holes 17 Using the access holes and a 13mm socket with extension secure winch using four non flange M8 hex head bolts B2 and lock washers B1 TIP Lift one corner of the winch slightly as you begin to install your first bolt Once all the winch bolts are installed torque the winch bolts to proper torque specificat...

Page 9: ...he battery Disconnect the small wire harness that leads to the contac tor remove zip tie Disconnect ground wire from winch Remove power cables that run from the battery to the top of the contactor Remove the winch mounting bolts Slide the winch out the drivers side of vehicle by flexing the radiator hose out of the way At this point you may choose to wire the Warn contactor or use the existing ele...

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