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©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

87731A0

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

BUMPER KIT

Part Number: 87722

Application:  Polaris Ranger RZR 900 2011+

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

  

 

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 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 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.

Read installation and operating instructions thoroughly.

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 87722

Page 1: ... 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 a...

Page 2: ...Neveroperatethisproductifyouareunder16yearsofage Neveroperatethisproductwhenundertheinfluenceofdrugs alcoholormedications Read installation and operating instructions thoroughly N O T E S T A B L E O F C O N T E N T S Parts List page x Tools Required page x Torque Specifications page x Installation page x Tips Troubleshooting page x Maintenance Care page x NOTE This bumper includes mounting holes ...

Page 3: ...rmor Plate A4 1 Cross Bar Support B1 2 M8 x 1 25 x 20mm Hex Head Bolt B2 2 5 16 Flat Washer B3 2 M8 x 1 25 Nylon Lock Nut with Flange C1 8 3 8 16 x 1 Hex Head Bolt C2 16 3 8 Flat Washer C3 8 3 8 16 Nylon Lock Nut Part Number Qty Description D1 4 1 4 20 U Bolt D2 8 1 4 Flat Washer D3 8 1 4 20 Nylon Lock Nut E1 2 3 8 Black Plastic Conduit not shown E2 2 1 4 Black Plastic Conduit not shown ...

Page 4: ...t and right wheel well guards at this time 2 Locate mounting holes to attach front support plate A3 to frame as shown in Figure 2 3 Attach front support plate A3 to frame as shown in Figure 3 Use M8 x 1 25 x 20mm hex head bolts and 5 16 flat washers on front side and M8 1 25 nylon lock nuts on back side Loosely secure hard ware using 13mm socket and wrench Figure 1 Figure 2 Figure 3 Remove left an...

Page 5: ...0 u bolts flatwashers and lock nuts to loosely attach to frame A 7 16 deep socket will be used to tighten in place later 5 Set bumper on top of front armor plate as shown in Figure 5 Loosely attach with four 3 8 16 hex head bolts flat washers and lock nut A flat washer should be used under head of bolt and on top of locknut A 9 16 socket and wrench can be used to loosely secure This will help you ...

Page 6: ...earance with radiator hose and rear crossmember on passenger side of vehicle 8 After all other fastners have been tightened install cross member support bracket A4 It attaches to the back side of the A2 and then to the frame of the vehicle Refer to the exploded view for attach ment Torque u bolt nuts as shown in Figure 4 to recom mended specifications of 8lb ft 10 8 N m Torque M8 x 1 25 hardware o...

Page 7: ... conduit is to be used for RT XT25 winches 3 8 ID conduit is to be used for RT XT30 winches 2 If no winch is mounted on bumper the set of holes as shown in Figure 10 can be used to mount a set of lights on top of bumper If winch is used there are holes on bottom of bumper as shown in Figure 11 that can be used to mount a set of lights RT XT 25 and 30 winch mount holes Figure 10 Figure 11 Light mou...

Page 8: ...2 Inspect all nuts and bolts on the bumper and related hardware prior to each use Tighten all nuts that appear to be loose Stripped fractured or bent bolts or nuts need to be replaced 3 Check all moving or rotating parts Remove debris that may inhibit the part from moving freely FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE BUMPER CAN RESULT IN PRODUCT FAILURE WHICH MAY RESULT IN VEHICLE DAMAGE AND...

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