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©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.

 1 

89548A0

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 Fax:

 1-503-722-3005

INSTALLATION INSTRUCTIONS

FRONT WINCH MOUNTING KIT

Part Number:  89535

Application:  2012 Can Am Renegade 800R

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

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.

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 ever operate this WARN product with damaged or missing parts.

Read installation and operating instructions thoroughly.

Содержание 89535

Страница 1: ...ION 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 Impact and Moving Parts Entanglement Hazard FAILURETO OBSERVETHESE INSTRUCTIONS COULD LEADTO SEVERE INJURY OR DEATH Alwaysuseextremecautionwhendrillingonan...

Страница 2: ...rts Entanglement Hazard FAILURETO OBSERVETHESE INSTRUCTIONS COULD LEADTO MINOR OR MODERATE INJURY AlwaystaketimetofullyreadandunderstandtheinstallationandOperationsGuideincludedwiththisproduct Neveroperatethisproductifyouareunder16yearsofage Neveroperatethisproductwhenundertheinfluenceofdrugs alcoholormedications Read installation and operating instructions thoroughly N O T E S B E F O R E Y O U B...

Страница 3: ...ead Capscrew not shown T O O L S R E Q U I R E D 13mm 10mm 17mm socket Wrench 13mm 10mm 17mm Standard Wrench Torx Set Short extensions for all socket wrenches T O R Q U E S P E C I F I C A T I O N S Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions 1 4 6mm 8 lb ft 10 8 N m 5 16 8mm 17 lb ft 23 0 N m 3 8 10mm 30 lb ft 40 7 N...

Страница 4: ...demarks ofWarn Industries Inc 4 89548A0 I N S T A L L A T I O N I N S T R U C T I O N S 1 Remove the plastic skid plate by removing the outside bottom and inside top bolts 2 Uninstall the upper bracket by removing the three long bolts and short bolt shown ...

Страница 5: ...lower mount bolts and the front two bolts 4 Remove the top two bolts to uninstall the top bumper bracket 5 Mount the winch using four M8 x 1 25 x 25mm bolts A7 supplied in this kit and lock washers supplied in winch kit 6 Pull the winch rope through the front window of the winch mount I N S T A L L A T I O N I N S T R U C T I O N S Winch Rope A7 ...

Страница 6: ...yellow towards the front 8 Install the gussets loosely using two M8 x 1 25 x 30mm bolts A6 and two locking nuts A3 on top and two countersunk bolts A4 with two locking nuts A3 on the bottom After all bolts are in place tighten all hardware to specifications on page 3 NOTE Review exploded view on page 3 for gusset orientation 9 Position winch mount assembly on vehicle I N S T A L L A T I O N I N S ...

Страница 7: ... supplied in this kit Note Install loosely at this time to allow for adjustment NOTE Review exploded view on page 3 11 Re attach the front of the plastic skid plate to aluminum bumper the front two bolts only at this time allowing the bottom of the skid plate to remain loose 12 Slide the bumper over the front fairlead tabs I N S T A L L A T I O N I N S T R U C T I O N S Factory bolt w A1 and A2 ...

Страница 8: ...loosely by installing the remaining two M8 1 25 x 30 long bolts A6 and spacers A5 with the factory nuts 14 Loosely install the lower factory bumper mounting bolts with nuts 15 Tightenall bumper hardware now 16 Install the bottom skid plate bolts to finish mounting the plastic skid plate I N S T A L L A T I O N I N S T R U C T I O N S ...

Страница 9: ...ies Inc 9 89548A0 17 Loosen the top roller of the fairlead to allow the wire synthetic rope through 18 Tighten the top roller down after the loop is through 19 Mount the fairlead to the front tabs using the fairlead hardware given I N S T A L L A T I O N I N S T R U C T I O N S ...

Страница 10: ...ghten all winch mounting bumper and skid plate hardware to torque specifications on page 3 Contactor installation and wiring 1 Mount the contactor to the contactor plate B1 and attach the plate mounting location using the two M8 bolts A8 provided Attach the red and black wires to the coordinating color marked contactor terminal using hardware with contactor I N S T A L L A T I O N I N S T R U C T ...

Страница 11: ...nd related hardware prior to each use Replace all parts that appears rusted or deformed Inspect all nuts and bolts on the plow plow mount and related hardware prior to each use Tighten all nuts and bolts that appear to be loose Stripped fractured or bent bolts or nuts must be replaced Check all cables prior to use Replace cables that are worn or frayed Check all moving and rotating parts Remove de...

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