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

106859A0

I N S T A L L A T I O N   I N S T R U C T I O N S

1.  Remove the front bumper.

a.  First pull the plastic tube caps from the front of the    

bumper.  

 

NOTE:  If you are changing from a Polaris winch to 

a WARN winch bumper mount  you will also need to 

remove the hook and fairlead at this time.

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 bumper bolts by lifting up 

and sliding off the metal flange.

Figure 1

Figure 2

Figure 3

Plastic tube cap

Hook and Fairlead

Upper grill tabs

Upper hardware

Lower hardware

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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