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WARN® INDUSTRIES

PAGE 1

72171 Rev A0

INSTALLATION INSTRUCTIONS

Kawasaki Mule Plow Mounting Kit

 

WARNING

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys 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.

‰

Alw

Alw

Alw

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Alwaaaaays 

ys 

ys 

ys 

ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye

injury.

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Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys use extreme caution when cutting and trimming during fitting.

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Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys remove jewelry and wear eye protection.

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Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er lean over battery while making connections.

‰

Ne

Ne

Ne

Ne

Nevvvvver r

er r

er r

er r

er rout

out

out

out

oute electrical cables:

e electrical cables:

e electrical cables:

e electrical cables:

e electrical cables:

o

Across any sharp edges.

o

Through or near moving parts.

o

Near parts that become hot.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

ys

ys

ys

ys insulate and protect all exposed wiring and electrical terminals.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

ys

ys

ys

ys install terminal boots as directed in installation instructions.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys use appropriate and adequate care in lifting components into place.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys insure components will remain secure during installation and operation.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys tighten all nuts and bolts securely, per the installation instructions.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

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.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er operate the vehicle on slopes greater than 10 degrees with the plow installed.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er stand or ride on the plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys replace all worn or damaged parts before operating.

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Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er operate this WARN product with damaged or missing parts.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

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

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.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

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.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

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

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.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.

INJURY HAZARD

Failure to observe these instructions could lead to severe injury or death.

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.   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.

WARN Part  Number:  71983

Application:  Kawasaki Mule 2003 and newer

Summary of Contents for 71983

Page 1: ...ng plow Alw Alw Alw Alw Alwa a a a ays ys ys ys ys perform regular inspections and maintenance on the plow mechanism fasteners cable and related hardware Alw Alw Alw Alw Alwa a a a ays ys ys ys ys replace all worn or damaged parts before operating Ne Ne Ne Ne Nev v v v ver er er er er operate this WARN product with damaged or missing parts Alw Alw Alw Alw Alwa a a a ays ys ys ys ys drive slowly ov...

Page 2: ...rior to installing the plow mount Right hand and left hand nomenclature throughout this document is with reference to side viewed from the operators position Table of Contents I Tools Required 3 II Torque Specifications 3 III Parts List 3 IV Installation 4 A Plow mount installation 4 B Plow support installation 11 NOTE Plow system is not intended for commercial use or applications Plow system may ...

Page 3: ...olt 1824 2 7 16 dia x 1 long bolt 7676 4 7 16 flat washer 710123 2 7 16 dia nylon lock nut 70566 6 1 2 dia x 3 long bolt 29060 6 1 2 dia nylon lock nut 69376 1 5 8 dia x 4 1 2 long bolt 69515 1 5 8 dia nylon lock nut 3693 2 Spacer 67622 4 5 8 outer dia x 3 4 long bronze spacer 68716 6 1 outer dia x 1 5 8 long spacer 72685 4 1 4 inner dia x 1 4 long spacer 69373 1 Plow roller fairlead 69375 1 3 1 4...

Page 4: ...ne 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 2 Begin by locating and removing the two rear bumper mounting bolts See Figure 1 and 2 Figure 1 Location of bumper bolts to remove Figure 2 Remove bumper bolts both sides Location of bolt to remove ...

Page 5: ... Locate the left and right mounting brackets in the kit Insert the four 5 8 dia x 3 4 long bronze spacers between the flanges of the mounting brackets with the 3 8 dia x 2 long carriage bolts See Figure 3 Figure 3 Install carriage bolt and bronze spacer to bracket Figure 4 Install brackets to vehicle lower frame Figure 5 Install bracket hardware washer both sides Install mounting bracket tab on in...

Page 6: ...orward toward bumper Trimmed opening should be approximately 3 8 1 2 wide by 3 long Related figures show the right hand side of vehicle viewed from the top through the hood opening Cut can be made most easily from the front of the vehicle through the front wheel fender opening See Figure 6 7 and 8 Figure 6 Location of material to be trimmed RHS shown Figure 7 Trimmed material Figure 8 Material rem...

Page 7: ...ure 9 Locate the top of the brace along the outer side of the frame member See Figure 10 and 11 Figure 9 Installation of brace LHS shown Figure 10 Locate top of brace to outside of upper frame tube Figure 11 Lower holes of brace fasten to mounting bracket Brace Vehicle Storage Tray Frame Member ...

Page 8: ...the top of the brace to the frame member using 1 4 x 1 wide x 1 3 4 long U bolt 1 4 flat washer and 1 4 nylon nut Do not tighten any hardware See Figure 13 9 Repeat the steps for mounting the brace for the other side See Figure 14 Figure 12 Brace fastened to mounting bracket Figure 13 Upper holes of brace fastened to vehicle frame tube Figure 14 Repeat brace mounting for other side Vehicle Storage...

Page 9: ...unting brackets centered on the plow support flanges See Figure 17 With the brackets centered to the support and square to the vehicle and screw drivers in place tighten down all mounting hardware in the following order 7 16 hardware mounting bracket to frame 5 16 dia x 1 1 2 wide x 2 1 4 long U bolt mounting bracket to bumper tube 3 8 dia x 2 long carriage bolts mounting bracket to brace 1 4 x 1 ...

Page 10: ...n routing the cable in or out of the rollerfairlead Operating the winch without the hook and hook strap can cause extreme bodily injury to the extremities such as the hands and fingers The winch needs to be off and switched to freespool when handling the winch cable without the hook WARNING Figure 20 Install grip clip onto winch hook Grip clip Winch hook Winch cable Clevis pin WARNING Do NOT opera...

Page 11: ... is no position 3 for the arm stop An arm stop is not needed if this position is selected There is no way to predetermine which setting the arms should be set in as each vehicle will react differently with a plow installed thus the user must use trial and error It is recommended to start in position 1 as this will fit the majority of vehicles For vehicles with greater than normal ground clearance ...

Page 12: ... out the other flange See Figure 23 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 22 Place the end of each top arm between the outside flanges and align them to top arm position 1 See Figure 22 23 Slide a 1 2 dia x 3 long bolt through top arm position 1 in ...

Page 13: ... bolt head are firmly resting against either side of the flanges but loose enough that the roller rotates freely about the bolt See Figure 24 26 Install the assembled guide roller and brackets onto the plow support by inserting tangs through slots in the support See Figure 25 Then rotate guide roller assembly up to align tab holes to support top flange holes Fasten with 3 8 dia x 1 1 4 long bolt a...

Page 14: ...nut See Figure 27 28 Attach one of the latches to a latch bracket Use two 3 8 dia x 1 1 4 long bolt and 3 8 nylon nuts See Figure 27 and 28 for part orientation for right hand and left hand latch assemblies Figure 27 Latch assembly left hand side Figure 28 Latch assembly right hand side Latch Bracket Latch Latch Latch Bracket Detent pin Lanyard fastening location ...

Page 15: ...e 29 and 30 30 Install latch assembly to top edge of stand and up against the side of plow support See Figure 31 Figure 29 Install stand right hand side shown Figure 30 Install stand slot to plow support tab Figure 31 Install latch assembly to stand and plow support Stand Slot Plow Support Tab Assembled Latch ...

Page 16: ... inner dia x 1 4 long spacers on each of the 1 4 bolts making sure that the spacers are fully engaged in the slot of the latch assembly See Figure 33 33 Carefully push bolts back through until they are flush with the latch bracket See Figure 34 Figure 32 Install 1 4 bolts Figure 33 Install spacers on 1 4 bolts Figure 34 Push 1 4 bolts and spacer back flush 1 4 Bolts ...

Page 17: ... ends of the bolts with two 1 4 dia nylon lock nuts and 1 4 flat washers See Figure 37 Tighten just snug and then loosen 1 8 1 4 turn The stand should move freely up and down on the support 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 35 Install retainer plate to plow support tab and engage F...

Page 18: ...h plow skids are in the blade Rock the support until both feet are flat on the ground At this point the feet skids and edge of the plow blade should all be resting flat on the ground If not adjust the plow skids or detent pins as needed CAUTION 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 t...

Page 19: ...operly vertically If they are at various heights follow the steps below Bottom edge of support receiver is HIGHER than the bottom surface of the plow mount Check that the tires have proper air pressure If adjustable adjust the shock settings to raise the vehicle If the tire pressure is correct and the shocks are raised to there highest setting then lower the plow support by removing the detent pin...

Page 20: ...support fully engages into the plow mount 7 Turn off the vehicle set the parking brake and walk over to the plow support Check to make sure that the plow support receivers are fully engaged in the plow mount You may have to push on the plow support or pull on the plow to get the receiver to go in as far as possible 8 Pull the detent pin out in one of the legs firmly slide and lift the stand until ...

Page 21: ... in one of the stands lift the stand until it locks fully into the plow mount place the detent pin back into the bottom hole in the plow support See Figure 40 Repeat on the other side 5 Double check that the plow is fully engaged into the system Pull and push on the plow blade to ensure nothing on the plow mount or plow support moves The blade should be solidly attached to the vehicle 6 MANUALLY r...

Page 22: ...ing the plow from the vehicle 9 Drive to an area with level solid ground Turn off the vehicle set the parking brake and walk over to the plow support 10 Remove the winch hook from the quicklink on the plow base Route the cable over the roller on the plow support and drape hook and cable over bumper tube Do not hook to vehicle bumper See Figure 43 11 Remove the detent pin for one of the stands Drop...

Page 23: ...h the winch cable and drop the feet then manually pull the plow support out of the mounting receivers If you are having trouble getting a latch to engage the plow mount it may need some simple adjustment With the stands in the down position push the plow support receivers into the plow mount as far as it will go Loosen the two 3 8 dia bolts holding the latch to the latch bracket Raise the stand up...

Page 24: ...aler to order To find a dealer nearest you please call the WARN Dealer locator line at 1 800 910 1122 Lanyard Service Kit No 71685 ARM Service Kit No 71683 Latch Assembly Service Kit No 72846 Support Stand Service Kit No 72845 Latch Hardware Service Kit No 72847 Bronze Spacer Service Kit No 72866 ARM Spacer Service Kit No 71707 ...

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