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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.
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PART TO BE INSTALLED
PART TO BE INSTALLED
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vsi2008-002-002_a
2 / 13 Instruction Sheet P/N 487 800 097
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PART TO BE INSTALLED
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
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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.
4 / 13 Instruction Sheet P/N 487 800 097
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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.
Instruction Sheet P/N 487 800 097 5 / 13
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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.
6 / 13 Instruction Sheet P/N 487 800 097
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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].
– Do not tighten nuts for the moment.
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.
Install M10 x 60 bolts [P4] and M10 nuts [P9].
– Do not tighten nuts for the moment.
vsi2008-002-020_a
Align upper support on the vehicle.
Install front bumper side bolts [14] and nutspreviously
removed.
– Do not tighten nuts for the moment.
vsi2008-002-021_a
Align U-bracket [15] (previously removed) on thewinch
support.
Install M8 x 25 bolts [P6] and M8 nuts [P10].
– Do not tighten nuts for the moment.
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.
Instruction Sheet P/N 487 800 097 7 / 13
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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.
8 / 13 Instruction Sheet P/N 487 800 097
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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].
Instruction Sheet P/N 487 800 097 9 / 13
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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.
10 / 13 Instruction Sheet P/N 487 800 097
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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].
Instruction Sheet P/N 487 800 097 11 / 13
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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.
12 / 13 Instruction Sheet P/N 487 800 097
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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.
Instruction Sheet P/N 487 800 097 13 / 13