WARN INDUSTRIES
PAGE 1
80546A1
©2009 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number:
80545
Application: Polaris Sportsman XP
WARNING
Alw
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Alwaaaaays
ys
ys
ys
ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
Alw
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ys
ys
ys
ys 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.
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ys
ys
ys
ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye
injury.
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ys
ys
ys
ys use extreme caution when cutting and trimming during fitting.
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ys
ys
ys
ys remove jewelry and wear eye protection.
Ne
Ne
Ne
Ne
Nevvvvver
er
er
er
er lean over battery while making connections.
Ne
Ne
Ne
Ne
Nevvvvver r
er r
er r
er r
er rout
out
out
out
oute electrical cables:
e electrical cables:
e electrical cables:
e electrical cables:
e electrical cables:
o
Across any sharp edges.
o
Through or near moving parts.
o
Near parts that become hot.
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ys
ys
ys
ys insulate and protect all exposed wiring and electrical terminals.
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ys
ys
ys
ys install terminal boots as directed in installation instructions.
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ys
ys
ys
ys use appropriate and adequate care in lifting components into place.
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ys
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ys insure components will remain secure during installation and operation.
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ys
ys
ys
ys tighten all nuts and bolts securely, per the installation instructions.
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ys
ys
ys
ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
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Alwaaaaays
ys
ys
ys
ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
Ne
Ne
Ne
Ne
Nevvvvver
er
er
er
er operate the vehicle on slopes greater than 10 degrees with the plow installed.
Ne
Ne
Ne
Ne
Nevvvvver
er
er
er
er stand or ride on the plow.
Alw
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ys
ys
ys
ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
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ys
ys
ys
ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
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ys
ys
ys
ys replace all worn or damaged parts before operating.
Ne
Ne
Ne
Ne
Nevvvvver
er
er
er
er operate this WARN product with damaged or missing parts.
Alw
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ys
ys
ys
ys drive slowly over bumpy and rough terrain. Driving at speeds that cause the plow to bounce while in the up position can
cause the winch to back-drive, causing the plow to work its way down. This may result in the plow impacting a stationary object
and cause damage to the vehicle and operator injury or death.
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ys
ys
ys
ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
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ys
ys
ys
ys be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious
damage to the ATV if the plow is raised too high. The plow blade will drop suddenly if the j-bolt breaks, so always be sure there
are no bystanders when you raise and lower the plow.
Ne
Ne
Ne
Ne
Nevvvvver
er
er
er
er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
Alw
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ys
ys
ys
ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
INJURY HAZARD
Failure to observe these instructions could lead to severe injury or death.
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 recommenda-
tions.
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.
