THUMPER FAB TF010602 Polaris Ranger Rear Winch Bumper Instruction Manual
- June 12, 2024
- THUMPER FAB
Table of Contents
Aluminum Audio Roofs Bumpers & Roll Cages UTV Accessories
REAR WINCH THUMPER BUMPER
ELITE EDITION
COMPATIBLE WITH
POLARIS RANGER NORTHSTAR/ RANGER 1000/RANGER XP 1000
P/N: TF010602
FEATURES
- CNC laser cut & formed 1/8” steel
- HD D-Ring mounts for safe recovery points
- CNC precision cut holes for ATV winch mount
- 6” LED Lightbar Ready
- Available in raw steel, ready for powder coating or paint match
- Extreme duty 3-stage powder coating options available
- Winch compatible up to 3,500 LB (Winch mounting area: 14.75” x 5” x 4.25” )
TOOLS REQUIRED
- 3/16” & 5/32” Allen Wrench
- 1/2”, 7/16”, & 9/16” Combination Wrench
- 1/2” & 9/16” Socket
- Drill with 1/4” bit
PARTS
| REF | QTY | PART DESCRIPTION |
|---|---|---|
| 1 | 1 | 5/16” x 1” Self-tapping Bolt |
| 2 | 2 | Mounting Brackets |
| 3 | 4 | 5/16” x 3/4” Socket Head Cap Screw* |
| 4 | 8 | 5/16” x 3/4” Hex Head Bolt* |
| 5 | 8 | 3/8” x 1.25” Hex Head Bolt |
| 6 | 2 | 5/16” x 1.25” Hex Head Bolt* |
| 7 | 8 | 1/4” x 1/2” Socket Head Cap Screw |
| 8 | 1 | Bumper Light Wiring Harness |
*(Install 5/16” flat washers & 5/16” nuts where indicated.)
BUMPER INSTALLATION INSTRUCTIONS
- Remove tailgate.
- Clean the four stock holes shown in diagram by threading BLEJ. in & out, discarding after use. Make sure holes are free of dirt, debris and factory powder coat residue.
- Install mounts to tailgate ® using hardware REF. 3. Thread bolts (HAND TIGHTEN ONLY) into all four holes. 4. Install mounts to frame °using hardware REF.
- (DO NOT TIGHTEN HARDWARE UNTIL STEP 7).
- Install Thumper Bumper to mounts ® using hardware REF. 5 & 6.
- Attach light bar covers using hardware REF. 7.
- Align bumper to vehicle, tighten all hard-ware, and replace tailgate.
- Continue to next page for wiring harness installation.
WIRING HARNESS & SWITCH INSTALLATION
-
Shift vehicle transmission into “PARK”. Turn ignition switch to “OFF” position and remove key.
-
Flip up passenger seat bottom (rear passenger seat for CREW), remove driver’s seat and underseat storage compartment, then disconnect black negative (-) cable from battery.
-
Gain access.
a. Remove hood.
b. Remove upper dash cupholder by removing two push pin rivets (A), then slide cupholder rearward. Retain rivets.
c. Tilt steering wheel to full down position. Detach instrument cluster hood by removing two push pin rivets
(B), then slide hood (with instrument cluster) rearward. Disconnect instrument cluster wiring harness. Retain rivets. -
Route switch connector (1E) from under-hood compartment rearward through firewall grommet (E) into upper dash compartment.
NOTE – Relay (1A), Polaris Pulse Bar connector (1G), tail-light connectors (1D) remain on forward side of firewall. Grommet (E) may be temporarily removed to facilitate harness passage. -
Attach relay to under-hood liner, forward of air intake ducts, then install relay (1A) using supplied self-tapping screw.
-
Open power cap on Polaris Pulse Bar at any open location, then plug in Pulse Bar connector (1G).
-
Lift vehicle bed to access wiring underneath. Connect black/blue reverse light connector (1F) to terminal under vehicle bed.
-
Route tail-light connectors (1D) forward across under-hood liner (as shown in Step 4), down through opening nearest the right front headlight, then run on top tof the intake tubes, then through central tunnel to rear under vehicle bed, joining connectors to taillights.
Ensure routing will prevent harness contact with hot components, sharp edges, or moving parts, but do NOT secure harness to vehicle at this time.
-
Route switch connector (1E) from firewall grommet (E) along dash support bracket towards LH side of vehicle, then downward towards switch blanks on lower LH side of steering wheel. Ensure routing will prevent harness contact with hot components, sharp edges, or moving parts, but do NOT secure harness to vehicle at this time.
-
Carefully cut out one rectangular switch blank from main dash panel.
-
Route switch connector (1E) out of switch opening, join to dash switch (2), then install switch into opening.
-
Secure switch connector branch of harness to front dash bracket.
-
Secure tail-light connector branch of harness to vehicle structure using edge clips and/or cable ties (as necessary).
-
Replace panels from step 3.
-
Reconnect black negative (-) cable to battery, then reinstall
DASH SWITCH WIRING
BLUE→ TOP(10)
WHITE → MIDDLE (2)
BLACK → BOTTOM (4)
Thumper Fab
5103 Elysian Fields Rd, Marshall, Tx 75672
Customer Service: 903-472-0928
www.thumperfab.com