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Warn 72008 Installation Instructions Manual

Warn 72008 Installation Instructions Manual

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.
do 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.
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 operate this WARN product with damaged or missing parts.
WARN INDUSTRIES
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
INSTALLATION INSTRUCTIONS
WINCH MOUNTING KIT
Application: Kymco MXU 250
CAUTION signals a hazard that may cause minor to moderate injury, if you
WARNING
INJURY HAZARD
PAGE 1
Part Number: 72008
72007A1

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Summary of Contents for Warn 72008

  • 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

    Tools Required ............... 3 III. Winch Modification ............4 Kymco MXU 250 Installation .......... 6 Recommended Contactor Location ......10 Maintenance/Care ............11 WARN INDUSTRIES PAGE 2 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 3: Parts List

    5/16-18 lock nut 1/4-20” x 1 1/8” x 1 3/4” U-bolt • Masking Tape. 1/4-20 lock nuts 5/16-18 x 3/4” bolt WARN INDUSTRIES PAGE 3 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 4: Winch Modification

    Lower Cap Screws Next remove the two upper cap screws, Fig. 2. Upper Cap Screws Figure 2: Remove Cap Screws WARN INDUSTRIES PAGE 4 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 5 Torque bolts to 45 in-lbs. The winch is now ready to be installed. Figure 5: Reinstall Hardware WARN INDUSTRIES PAGE 5 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 6: Kymco Mxu 250 Installation

    Fig. 8. Set the framework aside and save the fasteners to reinstall the framework. Fastner Locations Figure 8: Remove Framework WARN INDUSTRIES PAGE 6 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 7 Clean up the rough cut edges of the plastic and reinstall using original hardware. Figure 11: Clean and Replace Fan Shroud WARN INDUSTRIES PAGE 7 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 8 Tighten fastener to recommended torque of: 1/4 bolts 6 ft-lbs. (8 N-m) 5/16 bolts 11 ft-lbs. (15 N-m) Figure 14: Install Fairlead Bracket WARN INDUSTRIES PAGE 8 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 9 Figure 16: Cut Front Bumper 12. Reinstall the front bumper using the original 6 bolts. Figure 17: Reinstall Front Bumper WARN INDUSTRIES PAGE 9 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 10: Recommended Contactor Location

    Guide, supplied in the winch kit, for all wiring schematics and specific details on how to wire the winch to the ATV. Figure 19: Recommended Contactor Location WARN INDUSTRIES PAGE 10 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.
  • Page 11: Maintenance/Care

    Failure to perform regular inspections and maintenance on the winch, winch mount, and related hardware may result in vehicle damage and operator injury or death. WARN INDUSTRIES PAGE 11 72007A1 ©2005 Warn Industries, Inc. WARN® and the WARN logo are trademarks of Warn Industries Inc.