Warn 72008 Bedienungsanleitung
WARN INDUSTRIES PAGE1 72007A1
©2005 Warn Industries, Inc.
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.
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.
WARNING
INSTALLATION INSTRUCTIONS
WINCH MOUNTING KIT
Part Number: 72008
Application: Kymco MXU 250
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 INDUSTRIES PAGE2 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Table of Contents
I. Parts List ........................................................................3
II. Tools Required ...............................................................3
III. Winch Modification .........................................................4
IV. Kymco MXU 250 Installation ..........................................6
V. Recommended Contactor Location..............................10
VI. Maintenance/Care ........................................................11
Notice
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.
Caution
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o minor or moderato minor or moderat
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.
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.
WARN INDUSTRIES PAGE3 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. Tools Required
• Ratchet
• Sockets: 8mm, 10mm, 12mm, 7/16”, 1/2”,
• Wrenches: 7/16”,1/2”
• Allen Wrench 5/32
• Cutting Utensil
• Masking Tape.
I. Parts List
Ref Description Qty
A1 Mounting Bracket 1
A2 Fairlead Mounting Bracket 1
B1 5/16-18 x 1 1/4 x 1 3/4” U-bolt 2
B2 5/16” flat washer 8
B3 5/16-18 lock nut 4
B4 1/4-20” x 1 1/8” x 1 3/4” U-bolt 2
B5 1/4-20 lock nuts 4
C1 5/16-18 x 3/4” bolt 2
B4
B3
B2
B1
A2
A1
B5
WARN INDUSTRIES PAGE4 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
III. Winch Modification
The Warn 1.5ci winch needs to have the end housing
re-orientated to work with the Kymco winch mounting
kit.
1. Begin by placing winch in freespool.
Support the winch so that it will stand upright on the
workbench, Fig. 1. This will ensure that the winch
drivetrain will not be dislocated during disassembly.
2. Remove the two lower cap screws and nuts.
Next remove the two upper cap screws, Fig. 2.
Figure 2: Remove Cap Screws
Figure 1: Position the Winch Upright
Lower Cap Screws
Upper Cap Screws
Freespool
Lever
Position
WARN INDUSTRIES PAGE5 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
3 Lift the gear housing straight up off the gears.
Take care not to disturb the gear set.
4. Rotate the gear housing clockwise 90 degrees
and place back down over the gear set. It may
take slight twisting motion to have the housing
align and drop over the gear set.
5. Align holes and replace hardware securing the
endhousing back on the winch.
Torque bolts to 45 in-lbs.
The winch is now ready to be installed.
Figure 3: Lift Gear Housing
Figure 5: Reinstall Hardware
Figuere 4: Rotate and Replace Gear Housing
Rotate and Lower
WARN INDUSTRIES PAGE6 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
IV. Kymco MXU 250 Installation
1. Begin by removing the plastic bumper located on
the front of the ATV. Remove the four front bolts
and two bolts securing the bumper on the back
side, Fig. 6.
2. Set the bumper aside. Save the fasteners to
reinstall the bumper.
3. Remove the eight bolts that attach the front
framework, Fig. 8.
Set the framework aside and save the fasteners
to reinstall the framework.
Figure 8: Remove Framework
Figure 7: Remove Bumper
Figure 6: Remove Bumper Bolts
Remove
Remove
(behind) Remove
(behind)
Fastner Locations
WARN INDUSTRIES PAGE7 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
4. The fan shroud will need to be modified by
removing the lower portion to make room for the
winch. Remove the four bolts securing the fan
shroud to the radiator, Fig. 9.
5. Care needs to be taken when cutting the fan
shroud. When making preparation for the cut,
use masking tape or some other method to locate
a cut line so that not to cut off the lower mounting
holes of the shroud. Remove enough plastic so
that the winch will have clearance with the shroud.
A few trial fit-ups may be necessary before
enough plastic is removed. Fig. 10 shows an
approximate cutting line.
6. Clean up the rough cut edges of the plastic and
reinstall using original hardware.
Figure 9: Remove Fan Shroud
Figure 10: Mark Cut Line
Figure 11: Clean and Replace Fan Shroud
Screw
Locations
Cut Line
Retain
Mounting
Tabs
WARN INDUSTRIES PAGE8 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
7. Replace the front framework that was removed in
step 3 using the 8 original bolts that was securing
it.
Loosely install the winch mount (A1) using the
5/16” U-bolts (B1) and the 1/4” U-bolts (B4) as
shown in Fig.12.
8. Loosely mount the winch to the mounting bracket
using the two 5/16-18 x 3/4 inch bolt (C1)
provided with the mounting kit and the lock nuts
provided in the winch kit. Install hardware to the
upper two mounting holes only as shown in
Fig.13. The winch is to be mounted with gear
housing on the vehicles right side.
Note: Reference winch installation guide for
further assistance.
Figure 12: Install Winch Mount.
Figure 14: Install Fairlead Bracket
Figure 13: Install Winch
9. Install mount the fairlead bracket (A2) to the winch
mount using two 5/16-18 x 1 inch bolts and lock
nuts supplied with the winch kit, see Fig.14. With
the fairlead bracket mounted, adjust the winch
and bracket as needed and tighten all hardware.
Tighten fastener to recommended torque of:
1/4 bolts 6 ft-lbs. (8 N-m)
5/16 bolts 11 ft-lbs. (15 N-m)
A2
B1 A1
C1
B4
Freespool
Lever
WARN INDUSTRIES PAGE9 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
10. Mount the fairlead supplied in the winch kit to the
fairlead bracket, using the hardware supplied with
the winch kit.
11. The front bumper will need to be trimmed in the
same manner as the fan shroud to make
clearance for the mounting plate and the fairlead.
With masking tape, mark a cut line and trim as
necessary. A few trial fit-ups may be necessary
until enough material is removed for the bumper
to clear the mounting bracket and the fairlead, see
Fig. 16.
12. Reinstall the front bumper using the original 6
bolts.
Figure 15: Mounting the fairlead
Figure 16: Cut Front Bumper
Figure 17: Reinstall Front Bumper
Remove
WARN INDUSTRIES PAGE10 72007A1
©2005 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
V. 2005 Kymco MXU 250
Recommended Contactor
Location
1. Contactor Location - Step Three in the winch
Installation and Specification Guide:
Please refer to the Installation and Specification
Guide, supplied in the winch kit, for all wiring
schematics and specific details on how to wire
the winch to the ATV.
Notice
13. Double check to make sure that all fasteners are
tightened.
Note: Reference winch installation guide for
installing hook.
WARNING
Tighten all nuts and bolts securely. Failure to
check all nuts and bolts prior to use can result
in product failure which can lead to vehicle
damage and operator injury or death. Figure 18: Completed Winch Installation on the
Kymco MXU 250
Figure 19: Recommended Contactor Location
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