Warn 102770 - User Manual

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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

ATV PLOW ACCESSORY

Part Number: 102770

Application: 2003+ YAMAHA KODIAK 450/400

GENERAL SAFETY PRECAUTIONS

WARNING

Impact and Moving Parts Entanglement Hazard

FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH

• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.

• 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, re or personal injury.

• Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying chips can cause eye injury.

• Always use extreme caution when cutting and trimming during tting.

• Always remove jewelry and wear eye protection.

• Never lean over battery while making connections.

• Never route electrical cables:

o Across any sharp edges.

o Through or near moving parts.

o 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 ensure components will remain secure during installation and operation.

• Always tighten all nuts and bolts securely, per the installation instructions.

• Always operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.

• Always plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.

• Never operate the vehicle on slopes greater than 10 degrees with the plow installed.

• Never stand or ride on the plow.

• Always stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.

• Always perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

• Always replace all worn or damaged parts before operating.

• Never operate this WARN product with damaged or missing parts.

• Always 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.

• Always drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.

• Always 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.

• Never raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

• Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.

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 identies 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.

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Do you have a question about the Warn 102770 and is the answer not in the manual?

Summary

General Safety Precautions

Safety Warning - Impact and Moving Parts Entanglement Hazard

Alerts to severe injury or death from entanglement with moving parts if instructions are not followed.

Safety Caution - Moving Parts Entanglement Hazard

Alerts to minor/moderate injury from entanglement with moving parts if instructions are not followed.

Notice - Equipment Damage

Warns about potential equipment damage due to improper wiring or cable routing.

Installation Instructions Overview

Tools and Parts Required

Lists necessary tools and parts for installation, including torque specifications.

Mounting the Plow Mount

Details steps for attaching the Tab and Plow Mount to the vehicle skidplate and frame.

Attaching J-Bolt Bracket and Winch Cable

Describes how to attach the J-Bolt Bracket and connect the winch cable for plow lifting.

Maintenance and Care

Pre-Use Inspections

Instructions for inspecting parts, hardware, nuts, bolts, and cables before each use.

Summary

General Safety Precautions

Safety Warning - Impact and Moving Parts Entanglement Hazard

Alerts to severe injury or death from entanglement with moving parts if instructions are not followed.

Safety Caution - Moving Parts Entanglement Hazard

Alerts to minor/moderate injury from entanglement with moving parts if instructions are not followed.

Notice - Equipment Damage

Warns about potential equipment damage due to improper wiring or cable routing.

Installation Instructions Overview

Tools and Parts Required

Lists necessary tools and parts for installation, including torque specifications.

Mounting the Plow Mount

Details steps for attaching the Tab and Plow Mount to the vehicle skidplate and frame.

Attaching J-Bolt Bracket and Winch Cable

Describes how to attach the J-Bolt Bracket and connect the winch cable for plow lifting.

Maintenance and Care

Pre-Use Inspections

Instructions for inspecting parts, hardware, nuts, bolts, and cables before each use.

This document provides installation and operating instructions for the WARN ATV Plow Accessory, Part Number: 102770, designed for 2003+ Yamaha Kodiak 450/400 models. It emphasizes general safety precautions, installation procedures, and maintenance guidelines to ensure safe and effective use.

Function Description

The WARN ATV Plow Accessory is designed to enable an ATV to perform plowing tasks. It integrates with the ATV's frame and utilizes a winch (or electric actuator/manual lift) to raise and lower the plow blade. The system allows the ATV to clear snow or other materials by pushing them with the attached blade. The J-bolt mechanism is a critical safety feature, designed to break the connection between the plow and the winch if the plow is raised too high, preventing serious damage to the ATV.

Important Technical Specifications

Fastener Torque Specifications: The manual provides a comprehensive table for fastener torque specifications, crucial for secure assembly. These include:

1/4": 8 lb-ft (11 N.m)
5/16": 17 lb-ft (23 N.m)
3/8": 30 lb-ft (40 N.m)
7/16": 48 lb-ft (66 N.m)
1/2": 74 lb-ft (100 N.m)
9/16": 106 lb-ft (144 N.m)
5/8": 148 lb-ft (200 N.m)
3/4": 269 lb-ft (364 N.m)
M4: 2 lb-ft (3 N.m)
M5: 4.5 lb-ft (6 N.m)
M6: 7.5 lb-ft (10 N.m)
M8: 18 lb-ft (25 N.m)
M10: 37 lb-ft (50 N.m)

Parts List: The kit includes various components for assembly:

A1: 64224 Plow Mount (Qty: 1)
A2: 64227 Tab (Qty: 1)
A3: 62845 J-Bolt Bracket (Qty: 1)
B1: 31804 1/4" dia-1" long Bolt (Qty: 2)
B2: 35391 1/4" J-bolt (Qty: 2)
B3: 1320 1/4" Washer (Qty: 2)
B4: 6725 1/4" Nylock Nut (Qty: 4)
C1: 60869 5/16" dia-1 3/8" wide U-bolt (Qty: 4)
C2: 1324 5/16" Washer (Qty: 8)
C3: 2002 5/16" Nylock Nut (Qty: 8)
D1: 1827 3/8" dia-1" long Bolt (Qty: 1)
D2: 6779 3/8" Nylock Nut (Qty: 1)

Tools Required:

Rachet
7/16" Socket
7/16" Box Wrench
1/2" Socket or Box Wrench
9/16" Socket
9/16" Box Wrench
Drill
3/8" Drill Bit
Diagonal Cutter or Similar
Permanent Marker or Similar

Usage Features

Safety Precautions:

Read Manuals: Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels before operation.
Drilling Caution: Exercise extreme caution when drilling to avoid puncturing fuel lines, brake lines, electrical wires, or other objects. Inspect both sides of the material thoroughly.
Personal Protective Equipment: Wear safety glasses during installation to protect against flying metal chips. Remove jewelry and wear eye protection.
Electrical Safety: Insulate and protect all exposed wiring and electrical terminals. Never route cables across sharp edges, through or near moving parts, or near hot parts.
Operating Speed: Operate the vehicle at a walking speed (never exceed 5 mph or 8 km/h) with the blade installed.
Plowing Caution: Plow cautiously; impacts with hidden or stationary objects can cause sudden stops or loss of control.
Slope Restriction: Do not operate on slopes greater than 10 degrees with the plow installed.
Clearance: Stay clear of moving parts and joints. Keep others away during operation or adjustment.
J-Bolt Safety: The J-bolt is designed to break if the plow is raised too high, preventing damage. Always ensure no bystanders are present when raising/lowering the plow. Replace a deformed or broken J-bolt immediately with the spare.
Plow Height: Never raise the top of the plow above the ATV's headlights to avoid damage.
Bumpy Terrain: Drive slowly over bumpy terrain to prevent the plow from bouncing, which can cause the winch to back-drive and the plow to drop, potentially leading to impact with stationary objects, vehicle damage, or injury.

Installation Process:

Attach the Tab (A2) to the Plow Mount (A1) using 1/4" bolts (B1), washers (B3), and nylock nuts (B4).
Position the Plow Mount underneath the ATV, ensuring the Tab fits into the skidplate's rectangular opening.
Mark the eight open holes on the Plow Mount onto the skidplate using a permanent marker.
Remove the Plow Mount and drill through the marked locations on the skidplate (except the two outside ones) using a 3/8" drill bit.
Cut the sides of the skidplate to remove the two outside marked locations using diagonal shears.
Slide 5/16" U-bolts (C1) over the vehicle frame and through the drilled holes.
Re-position the Plow Mount, sliding the U-bolt ends through its open holes.
Secure the U-bolts with 5/16" washers (C2) and nylock nuts (C3).
Attach the plow blade to the Plow Mount using clip pins from the plow blade kit.
Attach the J-Bolt Bracket (A3) to the plow crossmember using a 3/8" bolt (D1) and nylock nut (D2). The bracket should be on the plow blade side, with the bolt head inside the bracket.
Route the winch cable over the roller fairlead and slide its loop end over the J-bolt hook.
Secure a J-bolt (B2) through the round hole in the J-Bolt Bracket with a 1/4" washer (B3) and 1/4" nylock nut (B4), ensuring the hook end sits in the slotted hole.

Maintenance Features

Regular Inspections:

Pre-Use Inspection: Before each use, inspect all parts of the winch, winch mount, and related hardware for rust or deformation.
Fastener Check: Inspect all nuts and bolts on the winch, winch mount, and related hardware. Tighten any loose nuts and replace stripped, fractured, or bent bolts or nuts.
Cable Inspection: Check all cables for wear or fraying and replace as needed.
Moving Parts: Check all moving or rotating parts and remove any debris that might inhibit their free movement.

Warn 102770 Specifications

General

Brand	Warn
Model	102770
Category	Offroad Vehicle
Language	English