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WARN INDUSTRIES

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60003 B2

INSTALLATION INSTRUCTIONS

ATV WINCH ACCESSORY

Winch Mount Kit: 

WARN PN 60004

Application: 

BOMBARDIER, TRAXTER AND QUEST

(Does not fit 3.0ci)

As you read these instructions, you will see 

NOTES

CAUTIONS

,

 

and 

WARNINGS

.  Each message has a specific

purpose.  

NOTES 

are additional information to help you complete a procedure.  

CAUTIONS 

are safety messages that

indicate a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  A 

CAUTION

may also be used to alert against unsafe practice or possible equipment damage.  

WARNINGS 

are safety messages that

indicate a potentially hazardous situation, which, if not avoided could result in serious injury.  

CAUTIONS  

and

WARNINGS 

identify the hazard, indicate how to avoid the hazard, and advise of the probable consequence of not

avoiding the hazard.  

PLEASE WORK SAFELY!

 

WARNING

SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING:

·  Read the Winch Operator Manual, the ATV Operator Manual, and all warning labels before operating or

using your ATV winch.

·  Always stay clear of moving parts and cables.  Keep others away when operating the winch.
·  Always inspect the winch mechanism, fasteners, cables, and adjustments before operating.  Replace all worn

or damaged parts before operating.

·  Always deactivate the winch before leaving the ATV unattended.

READ THE WINCH OPERATOR MANUAL BEFORE FREESPOOLING THE WINCH OR ATTACHING
THE HOOK.  BE CAREFUL WHEN CUTTING THE RUBBERBAND, THE CABLE IS PRESTRESSED
AGAINST THE DRUM AND MAY UNWIND QUICKLY AND WITHOUT NOTICE POSSIBLY HARMING
THE OPERATOR.

THE WINCH, WINCH PLATE, AND FAIRLEAD ASSEMBLY IS HEAVY.  USE PROPER LIFTING TECH-
NIQUE WHEN LIFTING THE ASSEMBLY.  KEEP TOES AND OTHER EXTREMITIES FROM BEING
UNDERNEATH THE ASSEMBLY IN CASE THE ASSEMBLY IS ACCIDENTLY DROPPED.  USE AN-
OTHER PERSONS ASSISTANCE IF NEEDED.

FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE WINCH PLATE, WINCH, AND FAIRLEAD
CAN RESULT IN PRODUCT FAILURE WHICH MAY RESULT IN VEHICLE DAMAGE AND OPERATOR
INJURY OR DEATH.  DOUBLE CHECK THAT ALL BOLTS ARE SECURELY TIGHTENED PRIOR TO
USE.

PERFORM REGULAR INSPECTIONS ON THE WINCH, WINCH MOUNT, AND RELATED HARDWARE.
NEVER OPERATE THE WINCH WITH DAMAGED OR MISSING PARTS.  FAILURE TO FOLLOW THIS
WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.

Summary of Contents for 60004

Page 1: ...r ATV winch Always stay clear of moving parts and cables Keep others away when operating the winch Always inspect the winch mechanism fasteners cables and adjustments before operating Replace all worn or damaged parts before operating Always deactivate the winch before leaving the ATV unattended READ THE WINCH OPERATOR MANUAL BEFORE FREESPOOLING THE WINCH OR ATTACHING THE HOOK BE CAREFUL WHEN CUTT...

Page 2: ...ached to the rack leave nuts on the bolts leaving the grey bumper still attached and loose Then remove the black plastic brush guard using a Phillips screwdriver and the 10mm wrench to remove the bottom screws Use a 15mm wrench to remove the front brush guard bolts Figure 1 2 Remove the two upper framebolts and the two lower frame bolts using a 13mm wrench and socket Figure 2 3 Swing out the whole...

Page 3: ...nstall the winch onto the mounting bracket with the two lower bolts and lock washers Figure 6 upper winch mounting bolts will be mounted later with the plastic brush guard and fairlead Note The motor should be on the right side when looking at the front of the ATV Torque lower winch bolts to approximately to 21 ft lbs 6 Install and tighten upper frame bolts bracket bolts and lower frame bolts to a...

Page 4: ...sh guard with the lower screws and attach the roller or hawse fairlead with the two remaining lock washers and 5 16 18 X 1 1 2 socket head bolts Figure 10 Tighten 21 ft lbs 28 N m Figure 8 WARNING FAILURE TO SECURELY TIGHTEN ALL BOLTS ON THE WINCH PLATE WINCH AND FAIRLEAD CAN RESULT IN PRODUCT FAILURE WHICH MAY RESULT IN VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH DOUBLE CHECK THAT ALL BOLTS ARE S...

Page 5: ...ve the cable from the steering cover at this time 3 Connect the red wire from the winch control switch and the red wire from the optional remote plug if equipped to the wire listed below according to your bike model This wire will be on the vehicle side of the speedometer electrical connector that is under the steering cover CAUTION Do not use the PURPLE wire on the key switch to hook up the winch...

Page 6: ...ck all cables prior to use Replace cables that look worn or frayed 4 Check all moving or rotating parts Remove debris that may inhibit the part from moving freely WARNING READ THE VEHICLE S OPERATOR MANUAL WINCH OPERATOR MANUAL AND ALL WARNING LABELS PRIOR TO OPERATION OF ATV AND WINCH III WINCH CONTROL SWITCH CONTINUED 4 When reinstalling the choke cable steering cover and all mounting hardware m...

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