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WARN INDUSTRIES

PAGE 2

72007A1

©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.

Table of Contents

I.

Parts List ........................................................................ 3

II.

Tools Required ............................................................... 3

III.

Winch Modification ......................................................... 4

IV.

Kymco MXU 250 Installation .......................................... 6

V.

Recommended Contactor Location .............................. 10

VI.

Maintenance/Care ........................................................ 11

Notice

Equipment Damage

‰

Always 

refer to the 

I

nstallation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific details

on how to wire this WARN product to your vehicle.

Read installation and operating instructions thoroughly.

Caution

Mo

Mo

Mo

Mo

Moving P

ving P

ving P

ving P

ving Par

ar

ar

ar

arts Entanglement Hazard

ts Entanglement Hazard

ts Entanglement Hazard

ts Entanglement Hazard

ts Entanglement Hazard

FFFFFailure t

ailure t

ailure t

ailure t

ailure to obser

o obser

o obser

o obser

o observvvvve these instructions could lead t

e these instructions could lead t

e these instructions could lead t

e these instructions could lead t

e these instructions could lead to minor or moderat

o minor or moderat

o minor or moderat

o minor or moderat

o minor or moderate injur

e injur

e injur

e injur

e injuryyyyy.....

‰

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 influence of drugs, alcohol or medications.

Read installation and operating instructions thoroughly.

Summary of Contents for 72008

Page 1: ...d 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 operate this WARN product with damaged or missing parts WARNING INSTALLATION INSTRUCTIONS WINCH MOUNTING KIT Part Number 72008 Application Kymco MXU 250 Your safety and the safety of others is very important...

Page 2: ...ment Hazard ts Entanglement Hazard ts Entanglement Hazard ts Entanglement Hazard ts Entanglement Hazard F F F F Failure t ailure t ailure t ailure t ailure to obser o obser o obser o obser o observ v v v ve these instructions could lead t e these instructions could lead t e these instructions could lead t e these instructions could lead t e these instructions could lead to minor or moderat o minor...

Page 3: ...mm 10mm 12mm 7 16 1 2 Wrenches 7 16 1 2 Allen Wrench 5 32 Cutting Utensil Masking Tape I Parts List Ref Description Qty A1 Mounting Bracket 1 A2 Fairlead Mounting Bracket 1 B1 5 16 18 x 1 1 4 x 1 3 4 U bolt 2 B2 5 16 flat washer 8 B3 5 16 18 lock nut 4 B4 1 4 20 x 1 1 8 x 1 3 4 U bolt 2 B5 1 4 20 lock nuts 4 C1 5 16 18 x 3 4 bolt 2 B4 B3 B2 B1 A2 A1 B5 ...

Page 4: ...ymco winch mounting kit 1 Begin by placing winch in freespool Support the winch so that it will stand upright on the workbench Fig 1 This will ensure that the winch drivetrain will not be dislocated during disassembly 2 Remove the two lower cap screws and nuts Next remove the two upper cap screws Fig 2 Figure 2 Remove Cap Screws Figure 1 Position the Winch Upright Lower Cap Screws Upper Cap Screws...

Page 5: ...e gear housing clockwise 90 degrees and place back down over the gear set It may take slight twisting motion to have the housing align and drop over the gear set 5 Align holes and replace hardware securing the endhousing back on the winch Torque bolts to 45 in lbs The winch is now ready to be installed Figure 3 Lift Gear Housing Figure 5 Reinstall Hardware Figuere 4 Rotate and Replace Gear Housing...

Page 6: ... Remove the four front bolts and two bolts securing the bumper on the back side Fig 6 2 Set the bumper aside Save the fasteners to reinstall the bumper 3 Remove the eight bolts that attach the front framework Fig 8 Set the framework aside and save the fasteners to reinstall the framework Figure 8 Remove Framework Figure 7 Remove Bumper Figure 6 Remove Bumper Bolts Remove Remove behind Remove behin...

Page 7: ...preparation for the cut use masking tape or some other method to locate a cut line so that not to cut off the lower mounting holes of the shroud Remove enough plastic so that the winch will have clearance with the shroud A few trial fit ups may be necessary before enough plastic is removed Fig 10 shows an approximate cutting line 6 Clean up the rough cut edges of the plastic and reinstall using or...

Page 8: ...the winch kit Install hardware to the upper two mounting holes only as shown in Fig 13 The winch is to be mounted with gear housing on the vehicles right side Note Reference winch installation guide for further assistance Figure 12 Install Winch Mount Figure 14 Install Fairlead Bracket Figure 13 Install Winch 9 Install mount the fairlead bracket A2 to the winch mount using two 5 16 18 x 1 inch bol...

Page 9: ...d to be trimmed in the same manner as the fan shroud to make clearance for the mounting plate and the fairlead With masking tape mark a cut line and trim as necessary A few trial fit ups may be necessary until enough material is removed for the bumper to clear the mounting bracket and the fairlead see Fig 16 12 Reinstall the front bumper using the original 6 bolts Figure 15 Mounting the fairlead F...

Page 10: ...ed in the winch kit for all wiring schematics and specific details on how to wire the winch to the ATV Notice 13 Double check to make sure that all fasteners are tightened Note Reference winch installation guide for installing hook WARNING Tighten all nuts and bolts securely Failure to check all nuts and bolts prior to use can result in product failure which can lead to vehicle damage and operator...

Page 11: ...e winch winch mount and related hardware Replace all that appears rusted cracked or deformed prior to use Inspect all nuts and bolts on the winch winch mount and related hardware prior to each use Tighten all nuts and bolts that are loose Missing stripped fractured or bent bolts or nuts need to be replaced immediately Check all cables prior to use Replace cables that are worn or frayed Check all m...

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