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WARN INDUSTRIES

PAGE 1

72007A1

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

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
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.

 

WARNING

INSTALLATION INSTRUCTIONS

WINCH MOUNTING KIT

Part Number:

 

72008

Application:

 Kymco MXU 250

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 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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