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WARN® INDUSTRIES

PAGE 1

80539 Rev A0

INJURY HAZARD

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

‰

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 dam-
aged.  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:

Across any sharp edges.
Through or near moving parts.
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 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: 80540

Application:

 YAMAHA GRIZZLY 450 ‘09’

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 80540

Page 1: ...s 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 80540 Application YAMAHA GRIZZLY 450 09 Your safety and the safety of others is very important To help you make informed decisions...

Page 2: ...kit for all wiring schematics and specific details on how to wire this WARN product to your vehicle Never overtighten the j bolt to the bracket Doing so will pinch the winch cable against the bracket damaging the cable Always put the end of the actuator cable through the slot in the Termination Bracket Terminating the cable through any other hole in the bracket will cause the bracket to not functi...

Page 3: ... 4 CAP SCREW M8 FLAT HD M8 1 25 X 16MM FLAT HEAD CAP SCREW 1 5 HEX HEAD CAP SCREW M8 1 25 X 20MM HEX HEAD CAP SCREW 2 6 HEX HEAD CAP SCREW M6 1 0 X 18MM HEX HEAD CAP SCREW 2 7 HEX NUT M8 1 25 LOCKING M8 1 25 LOCKING HEX NUT 2 8 HEX NUT M6 1 0 LOCKING M6 1 0 LOCKING HEX NUT 2 9 HEX NUT 1 4 20 LOCKING 1 4 20 LOCKING HEX NUT 4 10 WASHER FLAT 1 4 ZN 1 4 FLAT WASHER 6 11 WASHER FLAT 5 16 5 16 FLAT WASH...

Page 4: ...connecting the negative and positive leads to the battery figure 1 2 Remove the four bolts securing the front skid plate to the ATV frame figure 2 4 Remove the plastic rivets securing headlight bezels to the grab bar figure 3 5 Remove bolts securing grab bar to front rack figure 4 Figure 1 Figure 3 Figure 4 Remove REMOVE Remove ...

Page 5: ...hers and hex nuts figure 7 9 Place winch mounting bracket into position on the winch and attach using 2 M8 1 25 x 20mm hex head cap screws and lock washers in the forward two mounting holes On the motor side of the winch in the rear mounting hole use the M8 1 25 x 20mm countersunk cap screw On the clutch endhousing side of the winch use the M8 1 25 x 16mm countersunk cap screw figure 8 II Kit Inst...

Page 6: ... rear two mounting holes In the front mounting holes use 2 M6 1 0 x 18mm hex head cap screws flat washers and M6 1 0 locking hex nuts figure 10 12 Attach the front of the mounting plate to the grab bar using 2 1 4 20 u bolts flat washers and 1 4 20 locking hex nuts figure 11 13 Cut rubber band securing the winch wire rope to the winch drum Feed the wire rope loop through the roller fairlead and at...

Page 7: ...ailure to perform regular inspections and maintenance on the winch winch mount and related hardware may result in vehicle damage and operator injury or death III Maintenance Care Inspect all metal parts on the winch winch mount and related hardware Replace all that appears rusted or deformed prior to use Inspect all nuts and bolts on the winch winch mount and related hardware prior to each use Tig...

Page 8: ...e d entraîner des blessures mineures ou modérées si vous ne suivez pas les consignes Ce guide utilise le terme AVIS pour attirer votre attention sur des informations mécaniques importantes et le terme Remarque pour souligner des informations générales qui méritent une attention particulière Faites toujours extrêmement attention lorsque vous percez la carrosserie d un véhicule Veillez à ne pas perf...

Page 9: ...AVIS Équipement endommagé Reportez vous toujours au Guide d installation et de spécification fourni dans le kit de treuil pour tous les schémas de câblage et des informations détaillées concernant la façon de brancher ce produit WARN sur votre véhicule MISE EN GARDE Danger de happement par des pièces mobiles Le non respect des instructions peut entraîner des blessures mineures ou modérées Prenez t...

Page 10: ... VIS À TÊTE PLATE M8 VIS À TÊTE PLATE M8 1 25 X 16 MM 1 5 VIS À TÊTE HEXAGONALE VIS À TÊTE HEXAGONALE M6 1 25 X 20MM 2 6 VIS À TÊTE HEXAGONALE VIS À TÊTE HEXAGONALE M6 1 0X 18MM 2 7 ÉCROU HEXAGONAL DE BLOCAGE M8 1 25 ÉCROU HEXAGONAL DE BLOCAGE M8 1 25 2 8 ÉCROU HEXAGONAL DE BLOCAGE M6 1 0 ÉCROU HEXAGONAL DE BLOCAGE M6 1 0 2 9 ÉCROU HEXAGONAL DE BLOCAGE 1 4 20 ÉCROU HEXAGONAL DE BLOCAGE 1 4 20 4 10...

Page 11: ...igure 1 2 Retirer les quatre boulons qui retiennent le devant de la plaque de protection au châssis du VTT Figure 2 3 Retirer les rivets en plastique qui retiennent les cadrans de phare à la barre d appui Figure 3 4 Retirer les boulons qui retiennent la barre d appui au bâti avant Figure 4 II INSTALLATION DU KIT DE MONTAGE GRIZZLY 1 4 20 u bolts Retirer REMOVE Retirer Retirer ...

Page 12: ...aux de blocage M8 1 25 dans les deux trous de montage arrière Dans les trous de montage avant placer deux vis à tête hexagonale M6 1 0 x 18 mm des rondelles plates et des écrous hexagonaux de blocage M6 1 0 Figure 7 8 Placer le support de montage de treuil sur le treuil et le fixer à l aide de deux vis à tête hexagonale M8 1 25 x 20 mm et de rondelles de blocage dans les deux trous de montage avan...

Page 13: ...s à tête hexagonale M6 1 0 x 18 mm des rondelles plates et des écrous hexagonaux de blocage M6 1 0 Figure 10 11 Fixer le devant de la plaque de montage à la barre d appui à l aide de deux boulons en U 1 4 20 de rondelles plates et d écrous hexagonaux de blocage 1 4 20 Éviter de trop serrer serrer à un couple de serrage de 10 8 Nm 8 pi lb maximum Figure 11 II INSTALLATION DU KIT SUITE 12 Couper la ...

Page 14: ...e véhicule et provoquer des blessures ou la mort de l opérateur AVERTISSEMENT Le fait de ne pas inspecter et maintenir régulièrement le treuil la plaque de montage et le matériel de montage connexe peut finir par endommager le véhicule ou provoquer des blessures graves ou la mort de l opérateur AVERTISSEMENT III MAINTENANCE ET ENTRETIEN Inspectez toutes les pièces métalliques du treuil le montage ...

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