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Warn 80545 - User Manual

Warn 80545
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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
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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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outout
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e 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 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 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 genera
l
information worthy of special attention.

Table of Contents

Question and Answer IconNeed help?

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Summary

General Safety Precautions

Injury Hazard Warning

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

Additional Hazard and Equipment Notices

Moving Parts Entanglement Hazard

Failure to observe instructions could lead to minor or moderate injury.

Equipment Damage Warning

Follow specific guidelines to prevent damage to equipment and cables.

Tools Required

Parts List

Installation Guide: Polaris Winch Mount

Installation Guide: WARN Winch Mount

Maintenance and Care Procedures

Summary

General Safety Precautions

Injury Hazard Warning

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

Additional Hazard and Equipment Notices

Moving Parts Entanglement Hazard

Failure to observe instructions could lead to minor or moderate injury.

Equipment Damage Warning

Follow specific guidelines to prevent damage to equipment and cables.

Tools Required

Parts List

Installation Guide: Polaris Winch Mount

Installation Guide: WARN Winch Mount

Maintenance and Care Procedures

Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features
  5. Safety Information

This document provides installation instructions for the WARN Plow Mounting Kit, Part Number 80545, designed for the Polaris Sportsman XP. This kit facilitates the attachment of a plow to the ATV, requiring either a Polaris or WARN winch mount to be pre-installed on the vehicle.

Function Description:

The WARN Plow Mounting Kit serves as an intermediary bracket system that connects a plow assembly to an ATV equipped with a winch mount. Its primary function is to provide a secure and stable attachment point for a plow blade, enabling the ATV to be used for snow removal or other plowing tasks. The kit is specifically engineered to integrate with existing Polaris or WARN winch mounts, ensuring compatibility and proper alignment with the ATV's frame. It includes various components such as the plow mount itself, plow tabs, an adapter bracket for WARN winch mounts, and all necessary fasteners to establish a robust connection. The design allows for the plow to be raised and lowered, typically controlled by the ATV's winch system, making it a versatile accessory for utility applications.

Important Technical Specifications:

The kit includes a variety of fasteners with specific dimensions and torque requirements to ensure secure installation. Key fasteners include:

  • M10-1.50 x 25mm Hex Bolts (Qty: 4)
  • Flat Washer 3/8" (Qty: 2)
  • Capscrew M8-1.25 x 20mm (Qty: 2)
  • Plow Retaining Pin (Qty: 2)
  • Lock Washer M10 (Qty: 2)
  • Nut M10x1.50 (Qty: 2)

Torque specifications for tightening bolts are crucial for safety and proper function:

  • Lower M8x20mm bolts: 20 N-m (15 ft-lbs)
  • Plow mount to winch mount M10x25mm bolts: 25 N-m (18.5 ft-lbs)
  • Winch mount to frame bolts: 20 N-m (15 ft-lbs)

The kit requires specific tools for installation:

  • 3/8" Ratchet with 3-1/2" extension
  • Sockets: 10mm, 13mm, 16mm
  • Wrenches: 13mm, 16mm, 17mm

The plow mount is designed to fit around the frame cross bar where the lower skid pan bolts thread into. The WARN winch mount adapter bracket is specifically used when mounting with a WARN brand winch mount, while Polaris brand winch mounts utilize existing holes and do not require the adapter bracket.

Usage Features:

The installation process is detailed, with specific steps for both Polaris and WARN winch mounts. For Polaris Winch Mounts:

  1. Existing winch mount bolts are loosened, and lower skid pan bolts are removed (not reused).
  2. The plow mount is positioned under the vehicle, with tabs fitting around the frame cross bar.
  3. M8x20mm capscrews secure the plow mount to the frame.
  4. M10x25mm bolts with flat washers secure the plow mount to the winch mount.
  5. All bolts are then tightened to specified torque values.
  6. Plow mounting tabs are installed loosely on the plow tube assembly and tightened after the plow is fully assembled and installed.

For WARN Winch Mounts:

  1. The front skid plate is removed.
  2. The WARN winch mount is detached from the vehicle frame (caution is advised as it can fall).
  3. The fairlead is removed from the winch mount, and existing M10x1.5x20mm bolts are replaced with longer fasteners from the kit.
  4. The WARN winch mount adapter bracket is installed on the face of the winch mount using M10x1.5x25mm bolts.
  5. The fairlead is reinstalled over the adapter bracket, secured with lock washers and M10 nuts. The hook is then reattached.
  6. The WARN winch mount is reattached to the vehicle, with bolts left loose to allow for adjustment.
  7. The front skid plate is secured using only the upper bolts (lower bolts are not reused).
  8. The winch mount bolts are loosened again, and lower skid pan bolts are removed (not reused).
  9. The plow mount is positioned under the vehicle, secured with M8x20mm capscrews.
  10. The plow mount is secured to the winch mount with M10x25mm bolts and flat washers.
  11. All bolts are tightened to specified torque values.
  12. Plow mounting tabs are installed loosely on the plow tube assembly and tightened after the plow is fully assembled and installed.

Throughout the installation, notes emphasize the need for careful alignment and the possibility of rotating the winch mount to facilitate lining up holes. It also highlights that the j-bolt, which connects the plow to the winch, is designed to break if the plow is raised too high, preventing damage to the ATV. A spare j-bolt is included for replacement.

Maintenance Features:

Regular maintenance is crucial for the longevity and safe operation of the plow mounting kit:

  • Inspection of Metal Parts: All metal components of the plow, plow mount, and related hardware should be inspected for rust or deformation before each use. Any rusted or deformed parts must be replaced.
  • Fastener Check: All nuts and bolts on the plow, plow mount, and related hardware should be inspected before each use. Loose fasteners must be tightened, and any stripped, fractured, or bent bolts or nuts require immediate replacement.
  • Cable Inspection: All cables associated with the plow system should be checked for wear or fraying before use. Worn or frayed cables must be replaced.
  • Moving Parts: All moving and rotating parts should be checked to ensure they move freely. Any debris that might inhibit movement should be removed.

Safety Information:

The manual emphasizes several safety precautions:

  • Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels before operation.
  • Use extreme caution when drilling to avoid puncturing fuel lines, brake lines, electrical wires, or other objects.
  • Always wear safety glasses during installation to protect against flying metal chips.
  • Remove jewelry and wear eye protection.
  • Use extreme caution when cutting and trimming.
  • Never lean over the battery while 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.
  • Ensure components are secure during installation and operation.
  • Tighten all nuts and bolts securely to specified torques.
  • Operate the vehicle at a walking speed (max 5 mph/8 km/h) with the blade installed, even when raised.
  • Plow cautiously, as impacts with hidden objects can cause sudden stops or loss of control.
  • Do not operate on slopes greater than 10 degrees with the plow installed.
  • Stay 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 unexpectedly, potentially causing damage or injury.
  • Be aware of the j-bolt's purpose: it's designed to break if the plow is raised too high, preventing damage. Ensure no bystanders are present when raising/lowering the plow.
  • Never raise the plow above the ATV's headlights to avoid damage.
  • Always replace a deformed or broken j-bolt with the spare provided.
  • Do not operate if under 16 years of age or under the influence of drugs/alcohol.
  • Do not overtighten the j-bolt to avoid pinching the winch cable.
  • Ensure the actuator cable is routed correctly through the termination bracket slot to prevent improper function and reduced cable life.

Warn 80545 Specifications

General IconGeneral
BrandWarn
Model80545
CategorySnow Blower
LanguageEnglish