Warn 86766 - User Manual

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WARN® INDUSTRIES PAGE 1 86531 Rev A0

INSTALLATION INSTRUCTIONS

ATV Plow Blade

Part Number: 86766 (48”), 86768 (54”), or 86772 (60”)

Application: All Terrain Vehicles

Before You Begin

This kit also requires a plow tube base kit, a WARN specific vehicle plow mount, and lift mechanism such as a

winch, electric actuator, or universal manual lift. See your local dealer for part numbers and available kits.

Please note that the larger blades are very heavy and for some people may be too tiresome to lift with a manual

lift. Older plow tube base kits come with a set of skids and plow springs that will not be used in the installation

of this kit. Instead, use the skids and springs provided with the blade kit. Additionally, older plow base kits may

come with english units fasteners rather than the metric fasterners as described in these instructions. The kits

are compatible. Simply use the following guidelines; 8mm = 5/16”, 10mm = 3/8”, and 12mm = 1/2”. A list of

replacement parts, such as skids and wear bars, can be found on the last page of this document.

Table of Contents

I. Tools Required .............................................. 2

II. Torque Specifications .................................... 2

III. Parts List ....................................................... 2

IV. Installation ..................................................... 3

V. Tips/Troubleshooting ..................................... 5

VI. Maintenance/Care ......................................... 5

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 empha-

size genera

l information worthy of special attention.

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Summary

Installation

Assemble Plow Lever Arm

Assemble the plow lever arm using a shoulder bolt, spring, and lock nut, ensuring free rotation.

Attach Socket Screws to Base

Attach socket screws to the side flanges of the plow base with lock nuts, noting recommended hole placement.

Attach Wear Bar to Blade

Secure the wear bar to the plow blade using carriage bolts and lock nuts through square holes.

Attach Blade to Tube Base

Mount the plow blade to the tube base using a large carriage bolt, bushing, and lock nut.

Assemble Plow Springs

Assemble plow springs by hooking them onto the plow blade eyebolt and plow base side flange.

Attach Heavy-Duty Plow Skids

Attach heavy-duty plow skids to the plow blade using skid pins for adjustable height.

Summary

Installation

Assemble Plow Lever Arm

Assemble the plow lever arm using a shoulder bolt, spring, and lock nut, ensuring free rotation.

Attach Socket Screws to Base

Attach socket screws to the side flanges of the plow base with lock nuts, noting recommended hole placement.

Attach Wear Bar to Blade

Secure the wear bar to the plow blade using carriage bolts and lock nuts through square holes.

Attach Blade to Tube Base

Mount the plow blade to the tube base using a large carriage bolt, bushing, and lock nut.

Assemble Plow Springs

Assemble plow springs by hooking them onto the plow blade eyebolt and plow base side flange.

Attach Heavy-Duty Plow Skids

Attach heavy-duty plow skids to the plow blade using skid pins for adjustable height.

The document describes the installation and maintenance of an ATV Plow Blade, manufactured by WARN® Industries. This product is designed for use with All Terrain Vehicles (ATVs) to facilitate snow removal and other plowing tasks.

Function Description:

The WARN ATV Plow Blade is an attachment for ATVs that allows users to clear snow and other loose materials. It consists of a plow blade, a plow tube base kit (sold separately), a WARN specific vehicle plow mount (sold separately), and a lift mechanism such as a winch, electric actuator, or universal manual lift (sold separately). The plow blade is designed to be robust and features heavy-duty plow springs and skids to manage varying terrain and plowing conditions. The system allows for adjustment of the blade's angle and height to optimize performance for different surfaces and tasks.

Important Technical Specifications:

The plow blade is available in three sizes, each with a specific part number:

48" Straight Blade Kit: Part Number 86766 (PN 70948)
- Includes 48" Plow Blade (PN 70886) and 48" Wear Bar (PN 37566).
54" Straight Blade Kit: Part Number 86768 (PN 70954)
- Includes 54" Plow Blade (PN 70889) and 54" Wear Bar (PN 38734).
60" Straight Blade Kit: Part Number 86772 (PN 70960)
- Includes 60" Plow Blade (PN 70560) and 60" Wear Bar (PN 37098).

The hardware kit for all plows includes:

10mm dia Carriage Bolt (PN 70987) - 9 units (7 for 48" and 54" blades)
10mm dia Nylon Lock Nut (PN 69807) - 9 units (7 for 48" and 54" blades)
Heavy Duty Plow Spring (PN 69669) - 2 units
Heavy Duty Plow Skid (PN 68820) - 2 units
Skid Pin (PN 25397) - 2 units

Recommended Torque Specifications:

8mm diameter bolt and nuts: 12 ft-lbs (17 N-m)
10mm diameter bolt and nuts: 20 ft-lbs (28 N-m)
16mm diameter nut: 100 ft-lbs (136 N-m)

Tools Required for Installation:

Ratchet
Sockets: 13mm, 17mm, 18mm, 24mm
Box Wrenches: 13mm, 17mm, 18mm
Allen Wrenches: 8mm

Usage Features:

Adjustable Plow Lever Arm: The plow lever arm allows for easy adjustment of the blade's angle. It should rotate freely once installed correctly.
Adjustable Plow Undercut: Socket screws on the side flanges of the plow base can be placed in different holes to adjust the plow undercut. The middle-lower hole is recommended for initial setup. The hole closest to the blade provides less plow undercut, while the hole furthest from the blade provides more.
Heavy-Duty Plow Springs: Two heavy-duty plow springs are included to absorb impact and allow the blade to trip forward if it encounters an immovable object, protecting the ATV and the plow. The tension of these springs is adjustable by tightening the 8mm nuts on the eyebolts.
Adjustable Heavy-Duty Plow Skids: Two heavy-duty plow skids are provided to protect the plow blade and the plowing surface. The skid height can be adjusted in 5/32" increments by placing the skid pin through different holes in the skid sleeve.
- For gravel and decorative surfaces, skids should be set higher than the edge of the plow blade.
- For pavement and concrete surfaces, skids should be set at plow edge level.
- Failure to use skids or setting them incorrectly can lead to scratches on the roadway and reduced wear bar life.
Compatibility: The kit is compatible with older plow tube base kits, which may use English unit fasteners. Guidelines are provided for conversion: 8mm = 5/16", 10mm = 3/8", and 12mm = 1/2".

Maintenance Features:

Regular Inspections: Prior to each use, inspect all metal parts, nuts, bolts, and cables on the plow, plow mount, and related hardware.
Part Replacement: Replace any parts that appear rusted, deformed, stripped, fractured, or bent. Worn or frayed cables must also be replaced.
Tightening Fasteners: Tighten any loose nuts and bolts.
Clearance of Moving Parts: Ensure all moving and rotating parts are free of debris that could inhibit their movement.
Replacement Parts: A list of available replacement parts, including wear bars and heavy-duty skids/pins, is provided with their respective part numbers.
Troubleshooting: In case of problems, users are advised to:
1. Reference the installation instructions for tips or notes.
2. Contact the dealer where the kit was purchased.
3. Call an authorized WARN Service Center (contact information provided on the warranty sheet).
4. Contact WARN customer service at 1-800-543-9276 or via www.warn.com. When contacting support, users should have the part number (from the front of the instructions), date of purchase, and the make, model, and model year of their ATV readily available.

Safety Information:

The manual emphasizes the importance of safety through "WARNING," "CAUTION," and "NOTICE" signal words.

WARNING: Indicates a hazard that could cause serious injury or death if recommendations are not followed.
CAUTION: Indicates a hazard that may cause minor to moderate injury if recommendations are not followed.
NOTICE: Calls attention to important mechanical information.
Note: Emphasizes general information worthy of special attention. Careless installation and operation can result in serious injury or equipment damage. Users are instructed to read and understand all safety precautions and operating instructions before installing and operating the product. Failure to perform regular inspections and maintenance can lead to vehicle damage and operator injury or death.