Warn 87355 - 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 Sales/Customer Service: 1-503-722-3008

International Fax: 1-503-722-3005

INSTALLATION INSTRUCTIONS

PLOW MOUNTING KIT

Part Number: 87355

Application: 2011 + Polaris Sportsman 400, 500, 800

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 insure 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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Summary

General Safety Precautions

Warning: Impact and Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to severe injury or death. Always remove jewelry and wear eye protection.

Caution: Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury. Never operate this product if you are under 16 years of age.

Summary

General Safety Precautions

Warning: Impact and Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to severe injury or death. Always remove jewelry and wear eye protection.

Caution: Moving Parts Entanglement Hazard

Failure to observe these instructions could lead to minor or moderate injury. Never operate this product if you are under 16 years of age.

Overview

General Safety Precautions
Impact and Moving Parts Entanglement Hazard (WARNING)
Moving Parts Entanglement Hazard (CAUTION)
Equipment Damage (NOTICE)
Tools Required
Torque Specifications
Parts List
Installation Instructions
Maintenance / Care

This document provides installation instructions for the WARN Plow Mounting Kit, part number 87355, designed for the 2011 and newer Polaris Sportsman 400, 500, and 800 models. The kit facilitates the attachment of a plow to the specified ATV models.

General Safety Precautions:

The manual emphasizes the importance of safety during installation and operation. It warns against careless installation and operation, which can lead to serious injury or equipment damage. Users are instructed to read and understand all safety precautions and operating instructions before using the product. Signal words like "WARNING" and "CAUTION" are used to indicate the level of hazard. "WARNING" signifies a hazard that could cause serious injury or death if recommendations are not followed, while "CAUTION" indicates a hazard that may cause minor to moderate injury. "NOTICE" highlights important mechanical information, and "Note" emphasizes general information.

Impact and Moving Parts Entanglement Hazard (WARNING):

Failure to follow these instructions can lead to severe injury or death. Key safety guidelines include:

Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels before operating.
Exercise extreme caution when drilling on any vehicle. Ensure no fuel lines, brake lines, electrical wires, or other objects are punctured or damaged. Thoroughly inspect the drilling area (both sides) and relocate any potentially damaged objects to prevent vehicle damage, electrical shock, fire, or personal injury.
Always wear safety glasses during installation to protect against flying metal chips.
Use extreme caution when cutting and trimming during fitting.
Remove jewelry and wear eye protection.
Never lean over the battery while making connections.
Avoid routing 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 and adequate care when lifting components.
Ensure components remain secure during installation and operation.
Tighten all nuts and bolts securely according to installation instructions.
Operate the vehicle at a walking speed with the blade installed, never exceeding 5 mph (8 km/h), even with the blade up.
Plow cautiously; impacts with hidden or stationary objects can cause the vehicle to stop suddenly or go out of control.
Do not operate the vehicle on slopes greater than 10 degrees with the plow installed.
Never stand or ride on the plow.
Stay clear of moving parts and joints, and keep others away when operating or adjusting the plow.
Perform regular inspections and maintenance on the plow mechanism, fasteners, cable, and related hardware.
Replace all worn or damaged parts before operating.
Never operate this WARN product with damaged or missing parts.
Drive slowly over bumpy and rough terrain. Excessive speed can cause the plow to bounce, leading to the winch back-driving and the plow dropping, potentially impacting stationary objects and causing damage or injury.
Always drive at speeds that prevent the plow from bouncing and be aware of its position.
Understand that the j-bolt is designed to break, disconnecting the plow from the winch, to prevent serious ATV damage if the plow is raised too high. Be aware that the plow blade will drop suddenly if the j-bolt breaks, so ensure no bystanders are present when raising or lowering the plow.
Never raise the top of the plow above the ATV's headlights, as this can damage the vehicle and plow.
Always replace a deformed or broken j-bolt with the spare included in the kit.
Read installation and operating instructions thoroughly.

Moving Parts Entanglement Hazard (CAUTION):

Failure to follow these instructions can lead to minor or moderate injury.

Fully read and understand the installation and Operations Guide.
Do not operate this product if under 16 years of age.
Do not operate this product under the influence of drugs, alcohol, or medications.
Read installation and operating instructions thoroughly.

Equipment Damage (NOTICE):

Refer to the Installation and Specification Guide supplied with the winch kit for wiring schematics and details on wiring the WARN product to the vehicle.
Never overtighten the j-bolt to the bracket, as this will pinch and damage the winch cable.
Always route the actuator cable end through the slot in the Termination Bracket. Using any other hole will cause improper function and drastically reduce the cable's life.
Read installation and operating instructions thoroughly.

Tools Required:

13mm Wrench
13mm Socket
Socket Wrench

Torque Specifications:

1/4 (6mm): 8 lb. ft. (10.8 N-m)
5/16 (8mm): 17 lb. ft. (12.5 N-m)
3/8 (10mm): 30 lb. ft. (40.7 N-m)
7/16 (11mm): 50 lb. ft. (67.8 N-m)
1/2 (13mm): 75 lb. ft. (101.7 N-m)

Parts List:

The kit includes the following components:

Plow Mount (Qty 1, Ref A1)
Bracket RH (Qty 1, Ref A2)
Bracket LH (Qty 1, Ref A3)
Large Washers (Qty 1, Ref A4)
J Bolt Bracket (Qty 1, Ref A5)
M8 Hex Head Bolts (Qty 6, Ref B1)
Flat Washers (Qty 10, Ref B2)
Lock Nuts (Qty 4, Ref B3)
1/4-20 J-Bolt (Qty 2, Ref C1)
3/8-16 x 1 Hex Bolt (Qty 2, Ref C2)
3/8" Flat Washer (Qty 2, Ref C3)
3/8-16 Lock Nut (Qty 2, Ref C4)
1/4" Flat Washer (Qty 2, Ref C5)
1/4-20 Lock Nut (Qty 2, Ref C6)

Installation Instructions:

Locate the welded puck on the plow mount. Insert the puck into the hole as shown in Figure 1. Insert one hex head bolt and a flat washer through the hole with the puck, through the frame.
On the top side of the skid plate, place the large black washer over the bolt, along with a flat washer and lock nut. Do not tighten fully yet, but take up some slack (Figure 2).
Locate and position the RH bracket as shown in Figure 3 over the top of the frame. Attach it to the plow mount using two hex head bolts, four flat washers, and two lock nuts. Do not tighten at this time.
Place the left-hand bracket over the frame and align the holes with the plow mount. Insert the three remaining hex head bolts with three flat washers up through the three holes. Then, place three flat washers and lock nuts on the bolts (Figure 4).
Tighten the bolt with the large black washer first. Then, tighten the rest of the fasteners evenly, ensuring not to distort the mount excessively (Figure 5).

Maintenance / Care:

Inspect all metal parts on the plow, plow mount, and related hardware for rust or deformation before each use. Replace any affected parts.
Inspect all nuts and bolts on the plow, plow mount, and related hardware before each use. Tighten any loose nuts and bolts. Immediately replace stripped, fractured, or bent bolts or nuts.
Check all cables before use. Replace worn or frayed cables.
Check all moving and rotating parts. Remove any debris that might inhibit free movement.

The document concludes by reiterating the warning that careless installation and operation can result in serious injury or equipment damage, urging users to read and understand all safety precautions and operating instructions.