Warn 95160 - 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

FRONT PLOW MOUNT KIT

Part Number: 95160 and 98678

Application: 2015+ Polaris 570

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

Tools Required

Torque Specifications

Parts List

Installation Instructions

Vehicle Preparation

Steps 1-3: Remove front torx bolts, lower front plastic, and tow hook bolts from the vehicle.

Mounting Brackets

Steps 4-6: Install front plow mount bracket and M6 u-bolts, and remove wire harness zip ties.

Install Winch and Supports

Steps 7-9: Mount winch, install support brackets, and torque all hardware to specifications.

Attach Plow Assembly

Steps 10-14: Reinstall plastic, attach puck flanges to plow, install bolts, and insert retaining pins.

Maintenance and Care

Summary

General Safety Precautions

Tools Required

Torque Specifications

Parts List

Installation Instructions

Vehicle Preparation

Steps 1-3: Remove front torx bolts, lower front plastic, and tow hook bolts from the vehicle.

Mounting Brackets

Steps 4-6: Install front plow mount bracket and M6 u-bolts, and remove wire harness zip ties.

Install Winch and Supports

Steps 7-9: Mount winch, install support brackets, and torque all hardware to specifications.

Attach Plow Assembly

Steps 10-14: Reinstall plastic, attach puck flanges to plow, install bolts, and insert retaining pins.

Maintenance and Care

This document provides installation instructions and safety precautions for the WARN Front Plow Mount Kit, part numbers 95160 and 98678, designed for 2015+ Polaris 570 vehicles.

Function Description:

The WARN Front Plow Mount Kit is an accessory designed to attach a snowplow to the front of a Polaris 570 ATV. It provides the necessary structural components and hardware to securely mount a plow system, enabling the ATV to be used for snow removal or other light-duty plowing tasks. The kit integrates with the vehicle's existing frame and winch mount, creating a robust connection point for the plow push tube assembly.

Important Technical Specifications:

The manual outlines specific fastener torque specifications for various sizes, ensuring proper assembly and safety. These include:

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

The kit includes several key components:

Right Hand Front Plow Mount Bracket (Part No. 79226)
Hardware Kit (Part No. 95167)
Left Hand Front Plow Mount Bracket (Part No. 79225)
Front Plow Mount (Part No. 95161)
Right Hand Support Bracket (Part No. 95158)
Left Hand Support Bracket (Part No. 95159)

Tools required for installation include:

1/2" Socket
1/4" drive socket wrench
13 mm socket
13 mm wrench
1/4" drive, 10 mm deep socket
5mm allen wrench
Wire cutters
T27 Torx driver

Usage Features:

The plow mount kit is designed for straightforward installation, involving the removal of existing vehicle components (torx bolts, lower front plastic, flange head bolts below the tow hook), and then securing the new plow mount brackets and support brackets. The installation process requires careful attention to fastener torque specifications to ensure a secure and safe attachment. A winch mount is also installed, utilizing existing M8 flange head bolts. The design allows for the relocation of the wire harness to accommodate the new components. Once installed, the plow push tube assembly slides into the front plow mount pockets and is secured with 3/8" retaining pins.

Important safety guidelines for usage include:

Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels before operating.
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, as impact with hidden or stationary objects can 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.
Stay clear of moving parts and joints, and keep others away when operating or adjusting the plow.
Drive slowly over bumpy and rough terrain to prevent the plow from bouncing and potentially causing damage or injury.
Be aware that the j-bolt is designed to break, preventing serious damage to the ATV if the plow is raised too high. Always ensure no bystanders are present when raising or lowering the plow.
Never raise the top of the plow above the headlights of the ATV to avoid damage.
Always replace a deformed or broken j-bolt with the spare included in the kit.

Maintenance Features:

Regular inspection and maintenance are crucial for the longevity and safe operation of the plow mount kit. The manual recommends the following maintenance tasks:

Inspect all parts: Before each use, inspect all components of the winch, winch mount, and related hardware for rust or deformation. Replace any hardware that shows signs of wear.
Check nuts and bolts: Prior to each use, inspect all nuts and bolts on the winch, winch mount, and related hardware. Tighten any loose nuts, and replace any stripped, fractured, or bent bolts or nuts.
Cable inspection: Check all cables before use, replacing any that appear worn or frayed.
Moving parts: Check all moving or rotating parts and remove any debris that might inhibit their free movement.

The document emphasizes that careless installation and operation can lead to serious injury or equipment damage, urging users to thoroughly read and understand all safety precautions and operating instructions. It also notes that the lower front plastic of the vehicle may need to be trimmed for clearance of the plow mount and arms.