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Warn 89535 Installation Instruction

Front winch mounting kit

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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.
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.
• 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, fire or personal injury.
• Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury.
• Always use extreme caution when cutting and trimming during fitting.
• Always remove jewelry and wear eye protection.
• Never lean over battery while making connections.
• Never route electrical cables:
• Across any sharp edges.
• Through or near moving parts.
• 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 and operation.
• Always perform regular inspections and maintenance on the winch, winch mount and related hardware.
• Never ever operate this WARN product with damaged or missing parts.
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
©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
FRONT WINCH MOUNTING KIT
Application: 2012 Can Am Renegade 800R
G E N E R A L S A F E T Y P R E C A U T I O N S
W A R N I N G
Impact and Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH
Read installation and operating instructions thoroughly.
Part Number: 89535
1
CAUTION
89548A0

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Summary of Contents for Warn 89535

  • Page 1 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.
  • Page 2: Table Of Contents

    Equipment Damage • Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific details on how to wire this WARN product to your vehicle. Read installation and operating instructions thoroughly. N O T E S...
  • Page 3: Parts List

    5/16 17 lb. ft. (23.0 N-m) 10mm 30 lb. ft. (40.7 N-m) 7/16 11mm 50 lb. ft. (67.8 N-m) 13mm 75 lb. ft. (101.7 N-m) 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 4 Remove the plastic skid plate by removing the outside bottom and inside top bolts. Uninstall the upper bracket by removing the three long bolts and short bolt shown. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 5 Mount the winch using four M8 x 1.25 x 25mm bolts (A7) supplied in this kit and lock washers supplied in winch kit. Pull the winch rope through the front window of the winch mount. (A7) Winch Rope 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 6 (A3) on the bottom. After all bolts are in place, tighten all hardware to specifications on page 3. NOTE: Review exploded view on page 3 for gusset orientation. Position winch mount assembly on vehicle. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 7: Installation

    11. Re-attach the front of the plastic skid plate to aluminum bumper the front two bolts only at this time, allowing the bottom of the skid plate to remain loose. 12. Slide the bumper over the front fairlead tabs. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 8 14. Loosely install the lower factory bumper mounting bolts with nuts. 15. Tightenall bumper hardware now. 16. Install the bottom skid plate bolts to finish mounting the plastic skid plate. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 9 17. Loosen the top roller of the fairlead to allow the wire/synthetic rope through. 18. Tighten the top roller down after the loop is through. 19. Mount the fairlead to the front tabs using the fairlead hardware given. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 10 Mount the contactor to the contactor plate (B1) and attach the plate mounting location using the two M8 bolts (A8) provided. Attach the red and black wires to the coordinating color marked contactor terminal, using hardware with contactor. Contactor Contactor plate mounting Contactor plate location 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 11: Maintenance/Care

    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. 89548A0 ©2012 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.