Warn 102600 - User Manual

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WARN INDUSTRIES, INC. 12900 S.E. Capps Road,

Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000

Customer Service: 1-800-543-9276

Dealer Locator Service: 1-800-910-1122

International Fax: 1-503-722-3005

INSTALLATION INSTRUCTIONS

WINCH MOUNT KIT

Part Number: 102600

Application: 2019 HONDA TALON

GENERAL SAFETY PRECAUTIONS

WARNING

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to severe injury or death

• Always take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations.

• 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 damaged. 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:

o Across any sharp edges.

o Through or near moving parts.

o 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 instructions.

• Always perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

• Always replace all worn or damaged parts before operating.

• Never operate this WARN product with damaged or missing parts.

Read installation and operating instructions thoroughly.

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 identies 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.

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Summary

General Safety Precautions

Hazard Signal Word Definitions

Explains the meaning of WARNING, CAUTION, and NOTICE signal words used in the manual.

Impact and Moving Parts Safety

Provides critical safety instructions for preventing injury from moving parts and impacts during installation.

Additional Safety and Operation Rules

Covers further safety guidelines including age restrictions and operating under the influence.

Parts List and Specifications

Parts Identification

Lists all components included in the winch mount kit with part numbers and quantities.

Fastener Torque Specifications

Details required torque values for various fastener sizes during assembly.

Installation Guide

Vehicle Preparation and Bumper Removal

Instructions for removing the vehicle bumper and preparing the mounting area.

Winch and Mounting Plate Assembly

Steps for attaching the fairlead to the mounting plate and securing the plate to the winch.

Securing Mount Assembly to Vehicle

Guides on attaching the winch mount assembly to the vehicle's bumper and frame.

Final Tightening and Wiring

Instructions for final hardware tightening and completing winch wiring.

Maintenance and Care

Pre-Use Inspection and Replacement

Procedures for inspecting parts, hardware, and cables for wear or damage before each use.

Moving Parts Maintenance

Guidance on checking and cleaning moving or rotating parts to ensure free movement.

Summary

General Safety Precautions

Hazard Signal Word Definitions

Explains the meaning of WARNING, CAUTION, and NOTICE signal words used in the manual.

Impact and Moving Parts Safety

Provides critical safety instructions for preventing injury from moving parts and impacts during installation.

Additional Safety and Operation Rules

Covers further safety guidelines including age restrictions and operating under the influence.

Parts List and Specifications

Parts Identification

Lists all components included in the winch mount kit with part numbers and quantities.

Fastener Torque Specifications

Details required torque values for various fastener sizes during assembly.

Installation Guide

Vehicle Preparation and Bumper Removal

Instructions for removing the vehicle bumper and preparing the mounting area.

Winch and Mounting Plate Assembly

Steps for attaching the fairlead to the mounting plate and securing the plate to the winch.

Securing Mount Assembly to Vehicle

Guides on attaching the winch mount assembly to the vehicle's bumper and frame.

Final Tightening and Wiring

Instructions for final hardware tightening and completing winch wiring.

Maintenance and Care

Pre-Use Inspection and Replacement

Procedures for inspecting parts, hardware, and cables for wear or damage before each use.

Moving Parts Maintenance

Guidance on checking and cleaning moving or rotating parts to ensure free movement.

Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features
General Safety Precautions (summarized from the document)

This document provides installation instructions for a WARN Winch Mount Kit, Part Number 102600, designed for the 2019 Honda Talon. It includes general safety precautions, a parts list, torque specifications, detailed installation steps, and maintenance guidelines.

Function Description:

The WARN Winch Mount Kit is designed to securely attach a winch to the front of a 2019 Honda Talon vehicle. It provides a stable platform for the winch, allowing for its safe and effective operation in various recovery and utility tasks. The kit includes a winch mounting plate and two winch mount straps, along with necessary hardware, to integrate the winch seamlessly with the vehicle's bumper and frame. The installation process involves removing the vehicle's bumper, attaching the fairlead and mounting plate to the winch, securing the winch assembly to the bumper, and then reinstalling the bumper and connecting the winch wiring.

Important Technical Specifications:

Part Number: 102600
Application: 2019 Honda Talon
Components:
- Winch Mounting Plate (A1): Quantity 1, Part Number 102595
- Winch Mount Strap (A2): Quantity 2, Part Number 102596
- M8 x 20mm Hex Head Bolt (B1): Quantity 2, Part Number 99248
- M8 Lock Nut (B2): Quantity 2, Part Number 71588
- M8 x 25mm Hex Bolt (B3): Quantity 2, Part Number 65970
Tools Required for Installation:
- T30 Torx Bit
- Metric Wrench/Socket Set
- Ratchet Wrench
- Ratchet Extension
- Torque Wrench
Torque Specifications (General, unless otherwise specified):
- M4: 3 lb-ft (2 N.m)
- M5: 6 lb-ft (4.5 N.m)
- M6: 10 lb-ft (7.5 N.m)
- M8: 25 lb-ft (18 N.m)
- M10: 50 lb-ft (37 N.m)
- 1/4": 8 lb-ft (11 N.m)
- 5/16": 17 lb-ft (23 N.m)
- 3/8": 30 lb-ft (40 N.m)
- 7/16": 48 lb-ft (66 N.m)
- 1/2": 74 lb-ft (100 N.m)
- 9/16": 106 lb-ft (144 N.m)
- 5/8": 148 lb-ft (200 N.m)
- 3/4": 269 lb-ft (364 N.m)

Usage Features:

The winch mount kit facilitates the integration of a WARN winch with the 2019 Honda Talon, enabling the vehicle to perform winching operations. The design ensures a secure attachment, crucial for the high forces involved in winching. The installation process is detailed with step-by-step instructions and accompanying figures to guide the user. Key steps include:

Bumper Removal: Detaching the vehicle's bumper by removing specific Torx head screws and M8 hardware.
Fairlead and Winch Mounting Plate Installation: Attaching the fairlead (from the winch kit) to the winch mounting plate (A1), then securing the mounting plate to the winch itself using hardware from the winch kit. The winch is placed upside down for this step.
Winch Mount Assembly to Bumper: Sliding the winch mount assembly onto the bumper, aligning holes, and installing the winch mount straps (A2) with M8 x 20mm bolts (B1) and lock nuts (B2). A tip suggests attaching winch cables before this step for easier access.
Bumper Reinstallation: Sliding the bumper/winch assembly back onto the frame, leveraging plastic components as needed.
Securing the Assembly: Reinstalling factory Torx head screws and M8 hardware, and securing the rear portion of the winch mounting plate with longer M8 x 25mm bolts (B3).
Final Tightening and Wiring: Tightening all hardware to specified torque values and completing the winch wiring according to the winch kit instructions.

Maintenance Features:

Regular inspection and maintenance are crucial for the safe and reliable operation of the winch mount kit and the winch itself. The manual outlines the following maintenance practices:

Hardware Inspection: Before each use, inspect all parts on the winch, winch mount, and related hardware for rust or deformation. Replace any affected hardware.
Nut and Bolt Inspection: Prior to each use, inspect all nuts and bolts on the winch, winch mount, and related hardware for looseness. Tighten any loose fasteners. Replace any stripped, fractured, or bent bolts or nuts.
Cable Inspection: Before use, check all cables for signs of wear or fraying. Replace any worn or frayed cables.
Moving Parts Inspection: Check all moving or rotating parts for obstructions. Remove any debris that may hinder free movement.

General Safety Precautions (summarized from the document):

Read Instructions Thoroughly: Always read and understand all safety precautions and operating instructions before installing or operating the product.
Personal Safety: Wear safety glasses during installation to protect against flying metal chips. Remove jewelry and wear eye protection. Never lean over the battery when making connections.
Vehicle Safety: Exercise extreme caution when drilling to avoid puncturing fuel lines, brake lines, electrical wires, or other objects. Inspect areas to be drilled thoroughly and relocate any objects that may be damaged.
Electrical Safety: Insulate and protect all exposed wiring and electrical terminals. Install terminal boots as directed. Never route electrical cables across sharp edges, through or near moving parts, or near hot parts.
Product Integrity: Use appropriate care when lifting components. Ensure components remain secure during installation and operation. Tighten all nuts and bolts securely to specifications. Never operate the product with damaged or missing parts. Replace worn or damaged parts before operating.
Operator Restrictions: Never operate this product if under 16 years of age or under the influence of drugs, alcohol, or medications.
Hazard Warnings: The document uses "WARNING" for hazards that could cause serious injury or death, and "CAUTION" for hazards that could cause minor to moderate injury. "NOTICE" highlights important mechanical information, and "Note" emphasizes general information.

This comprehensive guide ensures that the WARN Winch Mount Kit is installed correctly and maintained properly, contributing to the safe and effective use of a winch on the 2019 Honda Talon.