Warn 71983 Installation Instructions Manual

Kawasaki mule plow 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.
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.
Failure to observe these instructions could lead to severe injury or death.
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Alwa a a a a ys ys ys ys ys Read the Plow Operator's Manual, the Winch Operator's Manual and all warning labels before operating.
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Alwa a a a a ys ys ys ys ys use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other
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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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Alwa a a a a ys ys ys ys ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye
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injury.
Alwa a a a a ys ys ys ys ys use extreme caution when cutting and trimming during fitting.
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Alwa a a a a ys ys ys ys ys remove jewelry and wear eye protection.
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Nev v v v v er er er er er lean over battery while making connections.
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Nev v v v v er r
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er r
er rout
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oute electrical cables:
out
out
out
e electrical cables:
e electrical cables:
e electrical cables:
e electrical cables:
Across any sharp edges.
o
Through or near moving parts.
o
Near parts that become hot.
o
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Alwa a a a a ys ys ys ys ys insulate and protect all exposed wiring and electrical terminals.
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Alwa a a a a ys ys ys ys ys install terminal boots as directed in installation instructions.
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Alwa a a a a ys ys ys ys ys use appropriate and adequate care in lifting components into place.
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Alwa a a a a ys ys ys ys ys insure components will remain secure during installation and operation.
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Alwa a a a a ys ys ys ys ys tighten all nuts and bolts securely, per the installation instructions.
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Alwa a a a a ys ys ys ys 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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Alwa a a a a ys ys ys ys 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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Nev v v v v er er er er er operate the vehicle on slopes greater than 10 degrees with the plow installed.
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Nev v v v v er er er er er stand or ride on the plow.
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Alwa a a a a ys ys ys ys ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
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Alwa a a a a ys ys ys ys ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
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Alwa a a a a ys ys ys ys ys replace all worn or damaged parts before operating.
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Nev v v v v er er er er er operate this WARN product with damaged or missing parts.
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Alwa a a a a ys ys ys ys ys drive slowly over bumpy and rough terrain. Driving at speeds that cause the plow to bounce while in the up position can
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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.
Alwa a a a a ys ys ys ys 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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Alwa a a a a ys ys ys ys ys be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious
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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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Nev v v v v er er er er 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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Alwa a a a a ys ys ys ys ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
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WARN® INDUSTRIES
INSTALLATION INSTRUCTIONS
Kawasaki Mule Plow Mounting Kit
Application: Kawasaki Mule 2003 and newer
CAUTION signals a hazard that may cause minor to moderate injury, if you do
INJURY HAZARD
WARN Part Number: 71983
WARNING
PAGE 1
72171 Rev A0

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Table of Contents
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Summary of Contents for Warn 71983

  • 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

    Before You Begin This kit also requires a Plow Blade kit, Utility Vehicle Plow Base kit, and a WARN winch mounted in the factory location for raising and lowering the plow. Please contact your nearest dealer for part numbers. Please note that the plow blade may be installed to the plow base prior to installing the plow mount.
  • Page 3: Tools Required

    5/8” outer dia x 3/4” long bronze spacer 68716 1” outer dia x 1-5/8” long spacer 72685 1/4” inner dia x 1/4” long spacer 69373 Plow roller fairlead 69375 3-1/4” roller 62134 Nylon bushings WARN® INDUSTRIES PAGE 3 72171 Rev A0...
  • Page 4: Installation

    Prior to installing the plow mount the vehicle must be prepped. If not already done so, install a WARN winch kit. Roller fairlead that comes with the winch kit does not need to be installed. This kit comes with a special fairlead to be used with plow.
  • Page 5 2. Do not tighten. See Figure 4 and 5. Figure 4 Install brackets to vehicle lower frame Figure 5 Install bracket hardware, washer both sides WARN® INDUSTRIES PAGE 5 72171 Rev A0...
  • Page 6 See Figure 6, 7 and 8. Figure 6 Location of material to be trimmed, RHS shown. Cut toward front bumper Figure 7 Trimmed material Material removed Figure 8 Material removed WARN® INDUSTRIES PAGE 6 72171 Rev A0...
  • Page 7 Figure 9 Installation of brace, LHS shown. Frame Member Brace Vehicle Storage Tray Figure 10 Locate top of brace to outside of upper frame tube. Figure 11 Lower holes of brace fasten to mounting bracket. WARN® INDUSTRIES PAGE 7 72171 Rev A0...
  • Page 8 Figure 13 Upper holes of brace fastened to vehicle frame tube. Repeat the steps for mounting the brace for the other side. See Figure 14. Figure 14 Repeat brace mounting for other side. WARN® INDUSTRIES PAGE 8 72171 Rev A0...
  • Page 9 Plow Support • 1/4” x 1” wide x 1 3/4” long U-bolt, brace to upper frame tube Figure 17 Mounting bracket alignment. Screw drivers used for alignment and plow support can now be removed. WARN® INDUSTRIES PAGE 9 72171 Rev A0...
  • Page 10 Operating the winch without the hook Figure 20 Install grip clip onto winch hook and hook strap can cause extreme bodily injury to the extremities such as the hands and fingers. WARN® INDUSTRIES PAGE 10 72171 Rev A0...
  • Page 11: Plow Support Installation

    WARN® INDUSTRIES PAGE 11 72171 Rev A0...
  • Page 12 Terminate with a 1/2” dia nylon lock nut. Tighten the nut until the nut and head of the bolt are resting against the surface of each outer flange. The arm should rotate freely around the bolt. WARN® INDUSTRIES PAGE 12 72171 Rev A0...
  • Page 13 Fasten with 3/ 8” dia x 1-1/4” long bolt and 3/8” dia nylon nut. See Figure 26. Figure 26 Fasten guide roller assembly at support top flange WARN® INDUSTRIES PAGE 13 72171 Rev A0...
  • Page 14 See Figure 27 and 28 for part orientation for right hand and left hand latch assemblies. Latch Latch Bracket Figure 27 Latch assembly left hand side. Latch Bracket Latch Figure 28 Latch assembly right hand side. WARN® INDUSTRIES PAGE 14 72171 Rev A0...
  • Page 15 Figure 30 Install stand slot to plow support tab 30. Install latch assembly to top edge of stand and up against the side of plow support. See Figure 31. Assembled Latch Figure 31 Install latch assembly to stand and plow support WARN® INDUSTRIES PAGE 15 72171 Rev A0...
  • Page 16 See Figure 33. Figure 33 Install spacers on 1/4” bolts 33. Carefully push bolts back through until they are flush with the latch bracket. See Figure Figure 34 Push 1/4’ bolts and spacer back flush WARN® INDUSTRIES PAGE 16 72171 Rev A0...
  • Page 17 If stand does not move freely then loosen additional incremental amounts. Until latch and stand move freely. Repeat from step 29-36 for other side. Figure 37 Install 1/4” washers and nuts WARN® INDUSTRIES PAGE 17 72171 Rev A0...
  • Page 18 Use proper lifting techniques when lifting the plow support. Bend at the knees, not your waist, and lift with your legs. Lifting with poor technique can lead to back injury. The support is heavy, so assistance may be required. WARN® INDUSTRIES PAGE 18 72171 Rev A0...
  • Page 19: Calibration

    • If the vehicle is properly loaded, then switch the arm and arm stop settings from position #1 to position #2 as described earlier in this document. WARN® INDUSTRIES PAGE 19 72171 Rev A0...
  • Page 20 Calibrate the plow every time new tires are added to the vehicle, the shock settings are changed, or weight is added/removed from the vehicle. Perform calibration at least once a season even if nothing has changed on the vehicle. WARN® INDUSTRIES PAGE 20 72171 Rev A0...
  • Page 21: Operation

    Figure 42 Plow attached to vehicle Turn the ignition switch to ON, and operate the winch to lift and lower the plow. The plow is now ready for operation and should look like Figure 42. WARN® INDUSTRIES PAGE 21 72171 Rev A0...
  • Page 22: Operating The Plow

    • WARN tells customers not to drive vehicles above 5 mph (8 km/h) with a plow installed. Risk of vehicular damage and bodily injury increases with speed.
  • Page 23: Tips/Troubleshooting

    Contact the dealer where you purchased the kit. Call an authorized WARN Service Center from the warranty sheet included in the kit. Please have the following information available before calling; part number (listed on front of instructions), date of purchase, and make, model, and model year of ATV.
  • Page 24 Service Kit No.72866 Service Kit No. 72846 Lanyard Service Kit No.71685 Contact your nearest WARN Dealer to order. To find a dealer nearest you, please call the WARN Dealer locator line at 1 800-910-1122 WARN® INDUSTRIES PAGE 24 72171 Rev A0...

Table of Contents