renegade winch kit - sheet...renegade winch kit (kit p/n 715 000 254) warning – for safety...

RENEGADE WINCH KIT(Kit P/N 715 000 254)

� WARNING– For safety reasons, this kit must be installed by an authorized BRP dealer.– This kit is designed for specific applicable models only (authorized BRP dealers will confirm

model(s)). It is not recommended for units other than the one (those) for which it was sold.– This instruction sheet MUST be given to the purchaser.

� WARNING– Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when

undergoing disassembly/assembly, always replace with a new one.– Torque wrench tightening specifications must strictly be adhered to.– Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools.– Unless otherwise specified, engine must be OFF when performing any operation on the vehicle.– Always be aware of parts that can move, such as wheels, transmission components, etc.– Some components may be HOT. Always wait for engine to cool down before performing work.

The following symbols may be used in this document:

Symbol Description

�WARNING Indicates a potentially hazardous situation which, if not avoided, could result inserious injury or death.CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle

components.

NOTE: Indicates supplementary information needed to fully complete an instruction.

FASTENER GRADE/TORQUE TO BE USED WHEN TORQUES ARE NOT SPECIFIED IN TEXT.FASTENERSIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade

M4 1.5 — 2 N•m(13 — 18 lbf•in)2.5 — 3 N•m

(22 — 27 lbf•in)3.5 — 4 N•m

(31 — 35 lbf•in)4 — 5 N•m

(35 — 44 lbf•in)

M5 3 — 3.5 N•m(27 — 31 lbf•in)4.5 — 5.5 N•m(40 — 47 lbf•in)

7 — 8.5 N•m(62 — 75 lbf•in)

8 — 10 N•m(71 — 89 lbf•in)

M6 6.5 — 8.5 N•m(58 — 75 lbf•in)8 — 12 N•m

(71 — 106 lbf•in)10.5 — 15 N•m(93 — 133 lbf•in) 16 N•m (142 lbf•in)

M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)

M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 72.5 N•m (53 lbf•ft)

M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft)

M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

NOTE: The illustrations in this document show typical construction of the different assemblies andmay not reproduce the full detail or exact shape of the parts; however, they represent parts that havethe same or similar function.

NOTE: Installation time is approximately 1.3 hours.

Printed in Canada. (vsi2008-002 en DM) Instruction Sheet P/N 487 800 097 1 / 13©2007 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

PART TO BE INSTALLED


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vsi2008-002-002_a

2 / 13 Instruction Sheet P/N 487 800 097


ITEM P/N DESCRIPTION QTY

P1 705 002 365 Upper support 1

P2 705 002 366 Lower support 1

P3 705 002 783 Spacer 4

P4 207 606 044 M10 x 60 Bolt 2

P5 207 685 044 M8 x 50 Bolt 2

P6 207 682 544 M8 x 25 Bolt 2

P7 207 682 044 M8 x 20 Bolt 4

P8 205 482 546 M8 x 25 Bolt 4

P9 233 201 414 M10 Flanged Nut 2

P10 233 281 414 M8 Flanged Nut 8

P11 232 581 414 M8 Nut 4

P12 234 082 410 M8 Washer 2

P13 415 079 900 Protector tube 1

P14 710 000 755 Switch Support 1

P15 250 000 029 M10 x 16 Screw 1

P16 234 101 601 M10 Washer 1

P17 250 000 153 6–32 Screw 2

P18 705 002 840 Warn® XT15 Winch Kit 1

P18a 77 051 Winch 1

P18b 67 752 Switch 1

P18c 66 138 Contactor 1

P18d 72 351 Hook 1

P18e 28 722 Fairlead 1

P18f 13 231 Cable tie 12

P18g 75 180 Warn® ATV RT/XT 15 Winch Installation Guide 1

P18h 75 012/013 Warn® ATV RT/XT 15 Winching Technique Guide 1Parts in shaded area are not illustrated

Warn® is a trademark of Warn industries inc.

Instruction Sheet P/N 487 800 097 3 / 13

INSTRUCTIONS

INSTRUCTIONS

Vehicle Preparation Procedure

vmr2007-059-001_a

Remove seat from vehicle using rear latch [1].

vsi2008-022-002_a

Lift front part of the central panel [2].

vsi2008-022-003_a

Pull off plastic studs from the grommets [3].

Remove central panel from vehicle.

vsi2008-002-003_a

Pull off service cover plastic studs from thegrommets [4].

vsi2008-002-004_a

Remove service cover [5] from vehicle by pullingit upward.

vsi2008-002-005_a

Remove side panels [6] from vehicle by pullingthem outward.


INSTRUCTIONS

Winch Installation Procedure

vsi2008-002-006_a

Align fairlead [P18e] on the lower support [P2].

Install 2x M8 bolts [P8] and 2x M8 nuts [P10].

Secure M8 bolts to 25 N•m (18 lbf•ft).

vsi2008-002-045_a

Align winch [P18a] on lower support [P2].

Install 2x M8 x 20 bolts [P7] and 2x M8 nuts [P11].

vsi2008-002-046_a

Align upper support [P1] on winch [P18a].

Install 2x M8 x 20 bolts [P7] and 2x M8 nuts [P11].

Ensure that winch supports flaps [A] holes arealigned.

Secure all M8 bolts to 25 N•m (18 lbf•ft).

vsi2008-002-009_a

Release winch cable [7] and insert it throughfairlead [P18e].

NOTE: The winch cable release handle is locatedon the top left side of winch.

vsi2008-002-010_a

Install hook [P18d] in winch cable [7] using thecotter pin.

NOTE: Make sure cotter pin [8] is properly twistedand locked on the shaft.

vsi2008-002-011_a

From underneath vehicle, remove front plasticdeflector bolts [9] and nuts.

– Keep them for re-use.

Remove front plastic deflector [10] from vehicle.


INSTRUCTIONS

vsi2008-002-012_a

Remove front bumper lower bolts [11] and nuts.

– Discard bolts and nuts.

vsi2008-002-013_a

Remove front bumper upper bolts [12] and nuts.

Remove U-bracket.

– Keep U-bracket for re-use.– Discard bolts and nuts.

vsi2008-002-014_a

Remove front bumper plastic grille bolt [13] and nut.

– Discard bolt and nut.

vsi2008-002-015_a

Remove aluminum frame side bolts [14] and nuts.

– Keep bolts and nuts for re-use.

Remove front bumper from vehicle.

vsi2008-002-016_a

Remove center strip [15] from front bumper.

– Discard bolts and nuts.

vsi2008-002-017_a

NOTE: Winch supports must be installed abovethe front bumper flap [B].

Align winch assembly on the front bumper.


INSTRUCTIONS

Install M8 bolts [P8], M8 washers [P12] and M8nuts [P10].

– Do not tighten nuts for the moment.

vsi2008-002-018_a

Install spacers [P3] between winch support andfront bumper.

Install M8 x 50 bolts [P5] and M8 nuts [P10].


vsi2008-002-019_a

Align front bumper assembly on the vehicle.

NOTE: Do not attempt to lift the bumper assemblyby hand alone. Use appropriate lifting device orhave assistance to share lifting stress in order toavoid risk of strain injuries.



vsi2008-002-020_a

Align upper support on the vehicle.

Install front bumper side bolts [14] and nutspreviously removed.


vsi2008-002-021_a

Align U-bracket [15] (previously removed) on thewinch support.



Starting from lower nuts towards upper nuts :

Secure all M10 nuts to 48 N•m (35 lbf•ft).

Secure all M8 nuts to 25 N•m (18 lbf•ft).

Re-install front plastic deflector [10] on vehicle.


INSTRUCTIONS

Electrical Installation Procedure

vsi2008-002-022_a

From rear of vehicle, locate solenoid plastic cover[16].

Remove solenoid plastic cover by pulling it towardthe outside.

vsi2008-002-023_a

Disconnect the negative pole BLACK CABLE [17]of vehicle battery.

vsi2008-002-029_a

Locate vehicle front fuse box [24].

vsi2008-002-030_a

Position winch contactor box [P18c] below frontfuse box.

– Place contactor mounting hole at the left sideof vehicle.

– Place contactor wires at the right side of vehicle.

NOTE: Make sure to leave a gap betweencontactor box and fuse box to ensure that fuse boxcover is easily removable.

On both sides of contactor [P18c], mark the placefor holes.

Remove front fuse box [24] from vehicle usingsides clips.


INSTRUCTIONS

vsi2008-002-031_a

Drill ø6,4 mm (1/4”) holes [25] into vehicle plasticcover.

vsi2008-002-032_a

From underneath plastic cover, locate and pull outthe 3 vehicle accessory wires [26].

NOTE: Vehicle accessory wires color are : green,blue and black.

Loosen M6 bolt [27] and nut that are located nearcoolant reservoir.

vsi2008-002-033_a

From underneath plastic cover, connect vehicleaccessory black wire (ground) terminal [28] in M6bolt.

Re-install and secure M6 nut.

NOTE: For MY 2009 and later, the vehicleaccessory black wire (ground) is already connectedon vehicle frame.

vsi2008-002-034_a

Connect winch contactors wires to vehicleaccessory wires as per following instruction :

– Green male contactor wire with green femalevehicle wire [29].

– Black female contactor wire with blue malevehicle wire [30].

vsi2008-002-027_a

Install winch contactor [P18c] cable along vehicleframe and follow the same routing as existingvehicle electrical cable.

Secure winch contactor cable with cable ties [P18f].


INSTRUCTIONS

vsi2008-002-026_a

Continue the winch contactor [P18c] cableinstallation along vehicle frame and follow thesame routing as existing vehicle electrical cable.

CAUTION: Make sure contactor cable is notsqueezed or pinched between any vehiclecomponents.

CAUTION: Make sure contactor cable is not incontact with any moving parts or sharp edges.

vsi2008-002-024_a

Locate starter solenoid [18].

Pull out red plastic cap from solenoid.

Remove hexagonal nut from positive pole.

Insert red wire terminal [19] of winch contactor[P18c] through red plastic cap.

Connect red wire terminal [19] in solenoid positivepole [20].

Secure hexagonal nut on solenoid positive pole.

Re-install red plastic cap on solenoid.

vsi2008-002-025_a

Locate solenoid negative pole [21].

Remove hexagonal nut from negative pole.

Connect black wire terminal [22] of winch contactor[P18c] in solenoid negative pole [21].

Secure hexagonal nut on solenoid negative pole.

Re-install solenoid plastic cover on vehicle.

vsi2008-002-028_a

Locate winch [P18a].

Cover winch wires with protector tube [P13].

Install protector tube along the vehicle brake line[23].

Secure protector tube with cable ties [P18f].

CAUTION: Make sure protector tube is notsqueezed or pinched between any vehiclecomponents.

CAUTION: Make sure protector tube is not incontact with any moving parts or sharp edges.


INSTRUCTIONS

vsi2008-002-035_a

Install winch contactor box [P18c] on the vehicleusing holes and cable tie [P18f].

– Place contactor mounting hole at the left sideof vehicle.

– Place contactor wires at the right side of vehicle.

Connect contactor end plug with winch end plug[31].

Fold extra length of contactor cable.

Place cable bundle at the rear of vehicle front fusebox [24].

Install winch plug [31] at the rear of vehicle frontfuse box [24].

Secure cable bundle using cable ties [P18f].

Secure winch plug [31] with cable ties [P18f].

Re-install front fuse box [24] on the vehicle.

Switch Installation Procedure

vsi2008-002-036_a

Align the switch support [P14] on the switch [P18b].

Install and secure 6–32 screws [17].

vsi2008-002-037_a

Align switch support [P14] on the brake housinghole [32] on left side of handlebar.

Install M10 screw [P15] and M10 washer [P16].

Secure M10 bolt.

vsi2008-002-038_a

Locate vehicle wiring harness [34].

NOTE: Vehicle wiring harness is located near thefront fuse box [24].


INSTRUCTIONS

Disconnect vehicle wiring harness end plug cap[33].

Remove end plug cap [33] from vehicle.

vsi2008-002-039_a

Remove clip [35] from end plug cap [33].

vsi2008-002-040_a

Install clip [35] on winch switch end plug [P18b].

vsi2008-002-041_a

Connect winch switch end plug [P18b] with vehiclewiring harness plug [34].

Re-install winch switch end plug [P18b] on vehicleusing clip [35].

vsi2008-002-042_a

Position winch switch cable along vehicle handlebarand follow the same routing as existing vehicleelectrical cable.

Secure winch switch cable with cable ties [P18f].

CAUTION: Make sure switch cable is notsqueezed or pinched between any vehiclecomponents.

CAUTION: Make sure switch cable is not incontact with any moving parts or sharp edges.

Reconnect the negative pole BLACK CABLE [17]on vehicle battery.

Re-install all removed plastics parts and seat byreversing vehicle preparation procedure.

Final InspectionVerify that all parts are properly tight and all loosewires / cables are tie wrapped tight.

Check winch for proper operation. The rope shouldspool in and out in the same direction indicated onthe switch.

You must read carefully the Warn® guides [P18g]and [P18h] to know and understand the winch andits operation.

� WARNINGTurn handlebar completely from one side tothe other making sure winch electrical cable donot exert a unwanted tension on the handlebar,throttle cable, brake hose and other wires.


INSTRUCTIONS

Warning and Caution

� WARNINGRead Warn® winch guides [P18g] and [P18h] andall warning and caution labels prior to operatingATV and winch.

This product comes with the following WARNINGtags containing important information.

vsi2008-002-043

vsi2008-002-044_en

Any person who intends to use this product shouldread and understand the information contained onthe tags before doing so.

Warn® is a trademark of Warn industries inc.


renegade winch kit - sheet...renegade winch kit (kit p/n 715 000 254) warning – for safety...

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