Warn 70737 - User Manual

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WARN INDUSTRIES PAGE 1 70736A3

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

INSTALLATION INSTRUCTIONS

PLOW MOUNTING KIT

Part Number: 70737

WARNING

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

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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 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 use extreme caution when cutting and trimming during fitting.

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ys remove jewelry and wear eye protection.

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er lean over battery while making connections.

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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 insulate and protect all exposed wiring and electrical terminals.

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ys install terminal boots as directed in installation instructions.

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ys use appropriate and adequate care in lifting components into place.

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ys insure components will remain secure during installation and operation.

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

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

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er operate the vehicle on slopes greater than 10 degrees with the plow installed.

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er stand or ride on the plow.

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

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

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ys replace all worn or damaged parts before operating.

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er operate this WARN product with damaged or missing parts.

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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 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 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.

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er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

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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

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

genera

l information worthy of special attention.

Applications:

2007+ Suzuki King Quad 450; 2009+ Suzuki King Quad 500;

2005+ Suzuki King Quad 700; 2008+ Suzuki King Quad 750

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Summary

General Safety Precautions

Injury Hazard Warning

Failure to observe instructions could lead to severe injury or death.

Hazard Signal Word Explanation

Defines WARNING for serious injury/death and CAUTION for minor injury.

Parts and Tools

Parts List

Lists the components included in the mounting kit with part numbers and quantities.

Tools Required

Lists the necessary tools for the installation process, including wrenches and sockets.

Installation Procedure

Fastener Torque Specifications

Details torque values for various fasteners used during installation.

Mounting Kit Installation Steps

Step-by-step guide for attaching the plow mount to the vehicle's underside.

Winch Cable Attachment

Instructions for connecting the winch cable to the plow using the J-Bolt bracket.

Maintenance and Troubleshooting

Maintenance and Care

Guidance on inspecting and maintaining the plow, mount, and hardware.

Troubleshooting Common Issues

Provides solutions for common installation problems like alignment and cable rotation.

Summary

General Safety Precautions

Injury Hazard Warning

Failure to observe instructions could lead to severe injury or death.

Hazard Signal Word Explanation

Defines WARNING for serious injury/death and CAUTION for minor injury.

Parts and Tools

Parts List

Lists the components included in the mounting kit with part numbers and quantities.

Tools Required

Lists the necessary tools for the installation process, including wrenches and sockets.

Installation Procedure

Fastener Torque Specifications

Details torque values for various fasteners used during installation.

Mounting Kit Installation Steps

Step-by-step guide for attaching the plow mount to the vehicle's underside.

Winch Cable Attachment

Instructions for connecting the winch cable to the plow using the J-Bolt bracket.

Maintenance and Troubleshooting

Maintenance and Care

Guidance on inspecting and maintaining the plow, mount, and hardware.

Troubleshooting Common Issues

Provides solutions for common installation problems like alignment and cable rotation.

Overview

Safety Information
Technical Specifications (Fastener Torque)
Usage Features
Maintenance Features
Installation Process
Troubleshooting

This document provides installation instructions for a Warn Plow Mounting Kit, part number 70737. This kit is designed for various Suzuki King Quad ATV models, including the 2007+ King Quad 450, 2009+ King Quad 500, 2005+ King Quad 700, and 2008+ King Quad 750. The primary function of this kit is to provide a robust mounting solution for a snowplow to the underside of the specified ATV models, enabling the ATV to be used for snow removal or other light-duty plowing tasks.

Safety Information:

The manual emphasizes safety throughout, using "WARNING" for hazards that could cause serious injury or death, and "CAUTION" for hazards that may cause minor to moderate injury. Key safety warnings include:

Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels before operating.
Exercise extreme caution when drilling to avoid puncturing fuel lines, brake lines, electrical wires, or other objects. Thoroughly inspect the area to be drilled on both sides.
Always wear safety glasses when installing to protect against flying metal chips.
Remove jewelry and wear eye protection.
Use extreme caution when cutting and trimming.
Never lean over the battery when making connections.
Never route electrical cables across sharp edges, through or near moving parts, or near hot parts.
Insulate and protect all exposed wiring and electrical terminals.
Install terminal boots as directed.
Use appropriate care when lifting components.
Ensure components remain secure after installation.
Tighten all nuts and bolts securely according to instructions.
Operate the vehicle at a walking speed (max 5 mph/8 km/h) with the blade installed, even when raised.
Plow cautiously; impacts with hidden or stationary objects can cause sudden stops or loss of control.
Never operate on slopes greater than 10 degrees with the plow installed.
Never stand or ride on the plow.
Keep clear of moving parts and joints, and keep others away during operation or adjustment.
Perform regular inspections and maintenance.
Replace worn or damaged parts before operating.
Never operate with damaged or missing parts.
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 impacting objects and causing damage or injury.
Be aware that the J-bolt is designed to break if the plow is raised too high, preventing serious damage to the ATV. The blade will drop suddenly if the J-bolt breaks, so ensure no bystanders are present when raising/lowering the plow.
Never raise the top of the plow above the ATV's headlights to avoid damage.
Always replace a deformed or broken J-bolt with the spare included in the kit.

Technical Specifications (Fastener Torque):

1/4" & M6: 8 lb. ft. (10.8 N-m)
3/8" & M10: 30 lb. ft. (40.7 N-m)
7/16": 50 lb. ft. (67.8 N-m)
1/2": 75 lb. ft. (101.7 N-m)
5/16" U-Bolt: 11 lb. ft. (14.9 N-m)

Usage Features:

The plow mount kit facilitates the attachment of a plow to the ATV. When used with a winch, the J-bolt bracket (part number 62845) is installed on the plow's cross-member. The winch cable runs through the roller fairlead and attaches to the J-bolt. The J-bolt's threaded end slides through round holes in the bracket, and its open end fits into a slotted hole. A 1/4" nut and washer secure the J-bolt, tightened until the open end drops into the slot, but not overtightened to avoid pinching and damaging the cable. If an electric actuator or manual lift is used, separate instructions from those kits apply.

Maintenance Features:

Regular maintenance is crucial for safe and effective operation:

Pre-use inspection: Inspect all metal parts of the plow, plow mount, and related hardware for rust or deformation. Replace any affected parts.
Fastener check: Inspect all nuts and bolts for looseness, stripping, fracture, or bending before each use. Tighten loose fasteners and replace damaged ones immediately.
Cable inspection: Check all cables for wear or fraying and replace if necessary.
Moving parts: Check all moving and rotating parts, removing any debris that might inhibit free movement.

Installation Process:

Fastener Configuration: Install the plow mount using the specified fasteners: 3/8" bolt with 3/8" Nylock nut, J-bolt with 1/4" nut, and 5/16" x 2.0" U-bolt with 5/16" Nylock nut.
Skid Plate Removal: Remove the factory skid plate from the ATV underside using a 10mm socket (typically six bolts).
Plow Mount as Template: Use the plow mount as a template to drill new holes in the skid plate.
Positioning: Place the plow mount 6" in front of the circular hole in the skid plate.
Marking and Drilling: Position the plow mount 3/16" away from the edge of the skid plate, ensuring it's perpendicular. Mark all hole locations on the skid plate with a sharp object and drill through with an 11/32" drill bit.
Reinstallation: Reinstall the skid plate with the original six fasteners. Install the plow mount by placing U-bolts over the frame, with threaded ends protruding through the plow mount. Attach 5/16" washers and nuts. All fasteners should be loosely installed initially. Slotting the skid plate holes may be necessary for U-bolt alignment.
Final Tightening: Securely tighten all 5/16" bolts to 11 lb. ft.
Plow Assembly (if not already done): Assemble the plow according to its instructions and attach it to the mount using the provided pins.
J-Bolt Bracket Installation (for winch operation): Install the J-bolt bracket (62845) to the plow's cross-member.
Winch Cable Attachment: Run the winch cable through the roller fairlead and around the J-bolt. Slide the J-bolt's threaded end through the round holes in the bracket, and the open end into a slotted hole. If the winch cable has a hook, move it out of the way.
J-Bolt Securing: Attach the 1/4" nut and washer to the J-bolt, tightening until the open end drops into the slot. Do not overtighten to avoid damaging the cable.

Troubleshooting:

The manual includes a troubleshooting section for common issues:

Difficulty aligning bolts with chassis holes: Check skidpan slot alignment with chassis holes when the mount is not compressed. Adjust skidpan or increase drilled hole diameter/slot in skidpan.
Difficulty getting plow pins through plow and plow mount: Ensure the plow and vehicle are on a flat, non-sloping surface. Use a smaller rod (e.g., drill bit) to align holes, then insert the plow pin.
Electric actuator cable not rotating within termination bracket: Ensure the cable is in the termination bracket slot, the cylindrical pin is attached to the cable, and the bracket leans toward the plow blade. Mount the bracket to the plow crossmember on the blade side, angling toward the blade. Slide the cable through the slot, slide the cylindrical pin over the cable end, and terminate with a 1/4" nut.

This comprehensive guide ensures proper installation, safe operation, and effective maintenance of the Warn Plow Mounting Kit, allowing ATV owners to maximize the utility of their vehicle for plowing tasks.