Warn 80545 Installation Instructions Manual Download Page 2

WARN INDUSTRIES

PAGE 2

80546A1

©2009 Warn Industries, Inc.

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

I. TABLE OF CONTENTS

Tools Required

page 2

Parts List

page 3

Installation

page 4-6

Polaris Winch Mount

page 4

WARN Winch Mount

page 5-7

Maintenance/Care

page 7

  CAUTION

Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury.

‰

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.

NOTICE

Equipment Damage

‰

Always 

refer to the Installation 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.

‰

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 function properly and will drastically reduce the life of the actuator cable.

Read installation and operating instructions thoroughly.

II.  TOOLS REQUIRED

 3/8" Rachet with 3-1/2" extension

-  Sockets: 10mm, 13mm, 16mm
-  Wrenches: 13mm, 16mm, 17mm

Summary of Contents for 80545

Page 1: ...ys stay clear of moving parts and joints Always keep others away when operating or adjusting plow Alw Alw Alw Alw Alwa a a a ays ys ys ys ys perform regular inspections and maintenance on the plow mechanism fasteners cable and related hardware Alw Alw Alw Alw Alwa a a a ays ys ys ys ys replace all worn or damaged parts before operating Ne Ne Ne Ne Nev v v v ver er er er er operate this WARN produc...

Page 2: ...e of drugs alcohol or medications Read installation and operating instructions thoroughly NOTICE Equipment Damage Always refer to the Installation 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 Never overtighten the j bolt to the bracket Doing so will pinch the winch cable against the bracket damagin...

Page 3: ...d if a winch mount has not been installed on the vehicle III PARTS LIST Ref Description Qty 1 Plow Mount 1 2 M10 1 50 x 25mm Hex Bolts 4 3 Flat Washer 3 8 2 4 Capscrew M8 1 25 x 20mm 2 5 Plow Retaining Pin 2 6 Plow Tab RH 1 7 Plow Tab LH 1 8 WARN Winch Mount Adapter Brkt 1 9 Lock Washer M10 2 10 Nut M10x1 50 Use Holes A if mounted with a Polaris Brand Winch Mount Use Holes B if mounted with a WARN...

Page 4: ...e side up first applying inward pressure on the skid plate mounting tabs to fit in between the plow mount tabs and around the cross tubing 3 Secure the plow mount to the winch mount Use a 16mm socket with two M10x25mm bolts with 3 16 flat washers Figure 4 Do not tighten all the way Note It may be necessary to rotate the winch mount upward for the mounting holes to line up with the plow mount holes...

Page 5: ...ch mount Use a 16mm socket with a 17mm wrench to loosen the two M10x1 5x20mm bolts that secure the fairlead to the winch mount These bolts will be replaced by longer fasteners provided in this kit 4 Place two M10x1 5x25mm bolts through the back of the face of the WARN winch mount Figure 7 Then place the WARN winch mount adapter bracket on the face of the winch mount feeding the bolts through the m...

Page 6: ...the WARN winch mount back on the vehicle mounting tabs and secure with bolts taken off in step 2 Do not tighten bolts all the way The winch mount needs to move slightly to install the plow mount Figure 10 7 Secure the front skid plate to the frame using only the upper bolts the lower bolts will not be used in this kit The front of the winch mount may have to be rotated upward to get the skid plate...

Page 7: ...nd a 13mm socket Figure 11 Do not tighten these Note It may be necessary to line one side up first applying inward pressure on the skid plate mounting tabs to fit in between the plow mount tabs and around the cross tubing 10 Secure the plow mount to the winch mount Use a 16mm socket with two M10x25mm bolts with 3 16 flat washers Figure 12 Do not tighten all the way Note It may be necessary to rota...

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