How to Install a Kodiak Warn Winch

Installing a Warn winch on your Kodiak ATV will help you out of sticky situations.

The Yamaha Kodiak ATV is a capable off-road machine. Its four-wheel drive system, light weight and knobby tires allow it to travel almost anywhere. For those few situations when your Kodiak gets stuck in the mud, a Warn winch is the tool for the job. It works by using a powerful electric motor to reel in a wire rope that has been attached to a stable object. Installing a Warn winch on your Kodiak can be done with a few common shop tools.

Things You'll Need

• Winch and mounting plate kit
• Ratchet wrench and socket set
• Torque wrench

Instructions

1. Remove the six bolts which fasten the front skid pan and set aside. Remove the plastic grab bar cover.

2. Remove the six fasteners that hold the front grab bar in place.

3. Loosen the two lower fasteners that secure the front grab bar. Do not remove these bolts.

4. Grasp the front grab bar and pull it off of the ATV. Place the winch mount into position inside the front grab bar.

5. Attach the front of the mounting plate with two U-bolts, spacers, washers and lock nuts provided. Only hand tighten at this time.

6. Align the mounting plate bolt holes with the grab bar bolt holes.

7. Place the winch and fairlead plate into position on top of the mounting plate. Secure with four bolts and lock washers.

8. Tighten the U-bolt nuts to seven foot-pounds of torque. Tighten the winch mounting bolts to 17 foot-pounds of torque.

9. Fasten the rear of the mounting plate to the ATV frame using two hex head screws, lock nuts and flat washers.

10. Attach the extension plate to the bottom tab on the grab bar using the button head bolts, washers, locks washers and hex nuts. Torque to two foot-pounds.

11. Fasten the grab bar cover to the grab bar using the hex washer head bolt. Only tighten for a snug fit.

12. Secure the grab bar in position using the six upper fasteners. Tighten these bolts to 10 foot-pounds of torque.

13. Reinstall the six skidpan fasteners removed at the beginning of the process. Tighten to seven foot-pounds of torque.

Tips & Warnings

• Practice proper winching technique prior to heading out on the trail.

References

• Warn: Installation Instrucations Yamaha Kodiak
• Yamaha: 2011 Kodiak 350

Resources

• Warn: The Basic Guide to Winching Techniques