Owners manual

ManualsBrandsWarn ManualsAutomotive83680 Chassis Body Armor

WARN INDUSTRIES PAGE 1 83688A0

WARN® and the WARN logo are trademarks of Warn Industries Inc.

INJURY HAZARD

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

INSTALLATION INSTRUCTIONS

SKID PLATE BODY ARMOR

Part Number: 83680

Application: 2009 POLARIS SPORTSMAN XP 550/850

WARNING



AlwAlw

Alw

ys ys

ys Read all warning labels before operating.



AlwAlw

Alw

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.



AlwAlw

Alw

ys ys

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

debris.



AlwAlw

Alw

ys ys

ys use extreme caution when cutting and trimming during fitting.



AlwAlw

Alw

ys ys

ys remove jewelry and wear eye protection.



NeNe

er er

er lean over battery while making connections.



AlwAlw

Alw

ys ys

insure components will remain secure during installation and operation.



AlwAlw

Alw

ys ys

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



AlwAlw

Alw

ys ys

ys inspect, tighten, and replace damaged hardware before use.



AlwAlw

Alw

ys ys

ys replace all worn or damaged parts before operating.



NeNe

er er

er operate this WARN product with damaged or missing parts.



NeNe

er er

er work under vehicle before properly securing vehicle.

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

genera

l information worthy of special attention.

NOTICE

• Product may affect airflow to vehicle engine and drivetrain components.

• Installation of this accessory may affect vehicle warranty.

• This product will NOT protect vehicle from all impacts and terrain conditions.

Summary of content (8 pages)

PAGE 1
INSTALLATION INSTRUCTIONS SKID PLATE BODY ARMOR Part Number: 83680 Application: 2009 POLARIS SPORTSMAN XP 550/850 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.
PAGE 2
Caution Mo ving P ar ts Entanglement Hazard Moving Par arts Failure tto o obser o minor or moderat e injur observve these instructions could lead tto moderate injuryy. Always take time to fully read and understand the installation and Operations Guide included with this product. Never operate this product if you are under 16 years of age. Never operate this product when under the influence of drugs, alcohol or medications. Read installation and operating instructions thoroughly. I.
PAGE 3
II. BEFORE YOU BEGIN Caution Injur Injuryy Hazard Failure tto o obser o injur observve these instructions could lead tto injuryy. Part edges may be sharp! Installation tip: • Apply electrical tape to clean dry vehicle components that will be in direct contact with aluminum skid plates. Tape will help protect painted finish against abrasion and can reduce tendency of squeaks. • Raising the vehicle on a hoist or ramps may ease installation of this product. III.
PAGE 4
VI. INSTALLATION: FRONT 1. Remove the 3 fasteners securing the rear skid plate to the bottom of the vehicle. Remove the 2 fasteners securing the front skid plate to the bottom of the vehicle. The rear skid plate will continue being removed, the front skid plate will not need to be removed for this installtion, figure 1. REAR Figure 1 2. Remove the 1 fastener securing the rear skid plate on the left side of vehicle just in front of the rear wheel.
PAGE 5
4. Remove the 2 fasteners securing the rear skid plate at the rear of vehicle. Retain these fasteners they will be used when installing the new skid plate. Remove the rear skid plate at this point, figure 4. REAR FASTENERS Figure 4 5. Place the front skid plate into position as shown in figure 5. Place the new skid plate on directly over the factory skid plate. Use 2 M61.0 flange head torx screws (B2) to secure the rear two holes of the skid plate. 6. Use 2 M6-1.0 flange head torx screws (B2), 2 M6-1.
PAGE 6
8. Place the rear skid plate into position and attach the bottom of the skid plate with 3, M61.0 flange head torx screws (B2), figure 7 M6 FASTENER Figure 7 9. Fasten the tabs located just in front of the rear tires with the 2 fasteners removed in steps 2 and 3, figure 8 FACTORY FASTENER Figure 8 10. Fasten the tabs located at the back of the rear skid plate with the 2 fasteners removed in step 4, figure 9 FACTORY FASTENER Figure 9 WARN INDUSTRIES PAGE 6 ©2009 Warn Industries, Inc.
PAGE 7
VII. MAINTENANCE/CARE • Inspect all metal parts and related hardware. Replace all parts that appear corroded, cracked or deformed prior to use. • Inspect all nuts and bolts and related hardware prior to each use. Tighten all nuts and bolts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced immediately. • Check skid plates protecting moving or rotating parts of the vehicle . Remove debris that may inhibit the part from moving freely.
PAGE 8