Warn 84705 Manual de usuario
WARN INDUSTRIES PAGE 1 84856A0
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 dam-
aged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, re or personal
injury.
Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying
chips can cause eye injury.
Always use extreme caution when cutting and trimming during tting.
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: 84705
Application: Honda Foreman 500 & Honda Rubicon
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 identies 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 PAGE 2 84856A0
Table of Contents
I. Parts List ..........................................................................3
II. Tools Required .................................................................3
III. Rubicon & Foreman Installation ...................................4-8
IV. Winch Wiring....................................................................9
V. Rubicon & Foreman Specic Wiring Instructions .....10-15
VI. Maintenance/Care .........................................................15
Caution
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor or moderate injury.
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 inuence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.
Notice
Equipment Damage
Always refer to the Installation and Specication Guide, supplied in the winch kit, for all wiring schematics and specic details
on how to wire this WARN product to your vehicle.
Read installation and operating instructions thoroughly.
Before You Begin
This kit is compatible with WARN’s line of ATV winches. Winch is sold separately. Please read WARN’s Winch-
ing Technique guide provided with the winch prior to use of this product.
WARN INDUSTRIES PAGE 3 84856A0
II. Tools Required
• Ratchet
• Sockets: 10mm, 12mm, 7/16”, 1/2”, 9/16”
• Wrenches: 1/2”, 9/16”
• Drill
• 1/4” drill bit
I. Parts List
Ref Description Qty
A1 Mounting Plate 1
B1 1/4-20 x 1” x 1 1/2” U-bolt 2
B2 1/4” at washer 4
B3 1/4-20 lock nut 4
B4 8mm-1.25 x 25mm bolt 2
B5 Spacer 2
WARN INDUSTRIES PAGE 4 84856A0
III. Rubicon & Foreman Installation
1. Begin by removing the front skid plate located on
the front of the ATV. Remove the four side 8mm
bolts and four bottom 6mm bolts securing the front
skid plate, gure 1. Save the fasteners as they
will be used later to reinstall the front skid plate.
2. Remove the four plastic rivets on each side of
the front plastic fascia, gure 2. Use a large
screw driver to carefully remove the center rivet.
After removing the center rivet, remove the rivet
housing. Save the fasteners as they will be used
to reinstall the front plastic fascia.
3. Remove the two 6mm bolts that attach the front
plastic fascia to the bumper, gure 3. Remove the
front plastic fascia at this time.
Figure1RemoveFrontSkidPlate
Remove
Remove
Remove
SkidPlate
Figure2RemovetheFourPlasticRivets
Remove
(bothsides)
Remove
(bothsides)
Figure3FrontPlasticFasciaBolts
Remove(bothsides)
WARN INDUSTRIES PAGE 5 84856A0
Figure5RemoveTopBumperBolts
Remove(bothsides)
Figure4FrontBumperBolts
Remove(bothsides)
Figure6RemoveBottomBumperBolts
Remove
4. Remove the two 6mm bolts that attach the front
bumper to the plastic headlight assembly, gure 4.
Save the fasteners as they will be used to reinstall
the front bumper.
5. Remove the two top 8mm bumper bolts that
attach the front bumper to the front rack, gure 5.
Save the fasteners as they will be used to reinstall
the front bumper.
6. Remove the two bottom bumper bolts that attach
the bumper to the bottom of the vehicle frame,
gure 6. Save the fasteners as they will be used
to reinstall the front bumper.
WARN INDUSTRIES PAGE 6 84856A0
Figure7RemoveFrameBumperBolts
Remove(bothsides)
Figure8AttachRollerFairlead
A1
Figure9InstallWinchontoMountingBracketandFairleadBracket
7. Remove the two middle bumper bolts that attach
the bumper to the middle of the vehicle frame,
gure 7. Remove the front vehicle bumper at this
time.
8. Attach the roller fairlead to the winch mounting
bracket (A2), gure 8. Use the two supplied 3/8”
dia bolts, nuts, and lock washers provided with the
winch as shown in gure 8. Tighten the two 3/8”
dia bolts to a recommended torque of 34 N-m (25
ft-lb).
Note: Atthispointintheinstallationrefertothe“Mo-
torRotationGuide”suppliedwiththismounting
kittotorotatethewinchmotor.Thiswillallow
themotorterminalstobeinthehorizontalpos-
tionandavoidinterferencewiththeheadlight
cowling.
9. Mount a 2.5ci winch to the mounting bracket (A1)
with four 5/16” dia bolts and lock washers supplied
with the winch kit. Mount the winch so that the
motor faces the right side of the vehicle, gure 9.
Tighten the bolts to a recommended torque of 17
N-m (12 ft-lb).
WARN INDUSTRIES PAGE 7 84856A0
10. Place the winch, mounting plate and roller fairlead
assembly into position on the front bumper, gure
10. Install two 1/4-20 x 1” x 1 1/2” U-bolts (B1),
four 1/4” at washers (B2) and four 1/4-20 lock
nuts (B3) that were supplied in the mounting kit,
gure 10. Do not tighten fasteners at this time.
11. Place the front bumper with attached winch
assembly back onto the vehicle frame. Reinstall
the two top and two bottom bumper bolts that
were removed in steps 5 & 6. Do not tighten at
this time.
12. Install the supplied 8mm-1.25 x 25mm bolts (B4)
into the middle bumper mounting location, place
the supplied spacer (B5) into postion between the
ATV frame and the winch mounting bracket tab
gure 11. Do not tighten at this time.
13. Reinstall the two 6mm bolts that were removed in
step 4. Reinstall the four rivet fasteners that were
removed in step 2. Reinstall the two 6mm bolts
that were removed in step 3. Do not tighten at
this time.
14. Reinstall the front plastic skid plate that was
removed in step 1, four side 8mm bolts and four
bottom 6mm bolts. Do not tighten at this time.
15. Tighten all fasteners to a recommended torque of:
6mm bolts - 12 N-m (9 ft-lb)
8mm bolts - 37 N-m (27 ft-lb)
1/4” U-bolts - 10 N-m (7 ft-lb) Figure12CompletedWinchInstallationontheRubicon
ClevisHook
8mmBolts
37N-m(27ft-lb)
8mmBolts
37N-m(27ft-lb)
8mmBolts
37N-m(27ft-lb)
8mmBolts
37N-m(27ft-lb)
6mmBolts
12N-m(9ft-lb)
Figure11BoltandSpacerInstallation
B4(bothsides)
B5(bothsides)
Figure10PlaceWinch,MountingPlateandRollerFairlead
AssemblyontoFrontBumper
B1,B2&B3
(bothsides)
WARN INDUSTRIES PAGE 8 84856A0
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.
Figure13HookAssembly-ExplodedView
WinchWireLoop
CotterPin
ClevisPin
ClevisPinTabs
Figure14HookAssembly-Assembled
16. Switch the winch clutch to freespool. Manually
feed the winch cable through the roller fairlead.
Attach the clevis hook, supplied with the winch,
to the end cable loop as shown in gure 12. This
is done by placing the winch wire loop between
clevis pin tabs on hook. Insert clevis pin through
clevis pin tabs and the winch wire loop. Insert
cotter pin into clevis pin retaining hole, gure 13
and gure 14.
17. Complete the winch installation as described in
the winch installation and specication guide that
came with the winch.
Winch and winch mount installation is now com-
plete and should look like gure 12. Proceed to
section IV, entitled “Winch Wiring”.
WARN INDUSTRIES PAGE 9 84856A0
IV. Winch Wiring
Please refer to the Installation and Specication
Guide, supplied in the winch kit, for all wiring
schematics and specic details on how to wire
the winch to the ATV.
Notice
Figure15UniversalWiringInstallationdiagram
Blue
(6 ga.)
Red
(20 ga.)
Black
(6 ga.)
Green
Black
Red
(6 ga.)
(Remote optional for
2.5ci)
Yellow
(6 ga.)
WARN INDUSTRIES PAGE 10 84856A0
V. Rubicon & Foreman Specic
Wiring Instructions
1. Contactor Location - Step Three in the
Installation and Specication Guide:
a. The contactor is located in the right rear inner fender,
on the right side of the rear tool box, gures 18, 19
& 20.
b. Remove the wire harness, gure 16, from the
bracket that holds the wire harness in position.
c. Using the drill and 1/4” drill bit, remove the top of the
rivet heads to remove the wire harness bracket.
d. Relocate the wire harness that was removed along
the rear rack tube, gure 18. Use a zip-tie to secure
the wire harness.
It should be noted that the following instructions
are ATV specic only. The following instructions
should be referred to as reference instructions to
assist wiring the winch from the Installation and
Specication Guide supplied in the winch kit.
Notice
Figure16RemoveWireHarnessfromBracket
WireHarness
Figure17RemoveWireHarnessBracket
RemoveWireHarness
Bracket
Figure18ContactorLocation-RightSideofToolBox
SecureWireHarness
withZip-Tie
RearRackTube
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