Warn 37851 - User Manual

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WARN INDUSTRIES PAGE 1 39527 Rev A1

INSTALLATION INSTRUCTIONS

ATV SNOW PLOW

Mounting Kit: PN 37851

Application: HONDA 400

WARNING

SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE

FOLLOWING.

• Read the Plow Operator’s Manual, the Winch Operator’s Manual, and all warning

labels before operating.

• Operate ATV at a walking speed with the blade installed. Do Not exceed 5mph

(8 km/h) even with the blade up.

• Plow Cautiously, impact with a hidden or stationary object may cause the ATV to

stop suddenly or go out of control.

• Do Not operate the ATV on slopes greater than 10° with the plow installed.

• Do Not stand or ride on the plow.

• Stay clear of moving parts and joints. Keep others away when operating or

adjusting plow.

• Inspect the plow mechanism, fasteners, cable, and adjustments before operating.

Replace all worn or damaged parts before operating.

• Lower the plow to the down position before leaving the ATV unattended.

TOOLS REQUIRED:

Ratchet

Sockets: 7/16, 1/2, 9/16”

Wrenches: 7/16, 1/2, 9/16”

Phillips Screwdriver (optional)

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 identifies 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 and Preparations

Safety Warnings and Precautions

Highlights severe injury or death risks if safety instructions are ignored, covering operation and maintenance.

Tools Required for Installation

Lists necessary tools for the ATV snow plow installation, including ratchets, sockets, wrenches, and a screwdriver.

Frame Mounting Bracket Installation

Parts List

Details the specific parts included in the mounting kit, such as bolts, nuts, and brackets, with part numbers and quantities.

Bracket Preparation and Mounting

Instructions for preparing the frame mounting bracket and attaching it to the ATV frame using U-bolts and nuts.

Plow Installation and Connection

Plow Attachment to Frame Bracket

Guides on sliding the plow into position and securing it to the frame bracket using pins and retaining clips.

J-Bolt Bracket and Winch Cable Connection

Details on attaching the J-bolt bracket and connecting the winch cable, emphasizing the J-bolt's safety function.

Summary

General Safety and Preparations

Safety Warnings and Precautions

Highlights severe injury or death risks if safety instructions are ignored, covering operation and maintenance.

Tools Required for Installation

Lists necessary tools for the ATV snow plow installation, including ratchets, sockets, wrenches, and a screwdriver.

Frame Mounting Bracket Installation

Parts List

Details the specific parts included in the mounting kit, such as bolts, nuts, and brackets, with part numbers and quantities.

Bracket Preparation and Mounting

Instructions for preparing the frame mounting bracket and attaching it to the ATV frame using U-bolts and nuts.

Plow Installation and Connection

Plow Attachment to Frame Bracket

Guides on sliding the plow into position and securing it to the frame bracket using pins and retaining clips.

J-Bolt Bracket and Winch Cable Connection

Details on attaching the J-bolt bracket and connecting the winch cable, emphasizing the J-bolt's safety function.

This document describes the installation and operation of the WARN ATV Snow Plow Mounting Kit, PN 37851, designed for the Honda 400 ATV. The primary function of this device is to enable the attachment of a snow plow blade to an ATV, allowing the ATV to be used for snow removal.

Function Description:

The WARN ATV Snow Plow Mounting Kit provides the necessary hardware and instructions to securely attach a snow plow to a Honda 400 ATV. It consists of a frame mounting bracket, J-bolts, U-bolts, and various nuts and bolts. The system is designed to allow the plow to be raised and lowered, typically using a winch (which requires a roller fairlead). A key safety feature is the J-bolt mechanism, which is designed to break under excessive force, protecting both the plow and the ATV from damage.

Important Technical Specifications:

Mounting Kit PN: 37851
Application: Honda 400 ATV
Fasteners:
- 3/8-16 x 1" Hex Bolt (PN 1827)
- 5/16" Nylock Nut (PN 2002)
- 1/4" Nylock Nut (PN 6227)
- 3/8" Nylock Nut (PN 6779)
- 5/16" U-Bolt (5/16-18 x 1 1/4 x 2) (PN 60870)
Mounting Components:
- J-Bolt (PN 35391)
- Frame Mounting Bracket (PN 39522)
- J-Bolt Mount (PN 62845)
Torque Specifications:
- 5/16" Nylock nuts on U-bolts: Approximately 15 ft-lb (20 N-m)
- 3/8" Nylock nut on J-bolt bracket: Approximately 20 ft-lb (28 N-m)
Operational Speed Limit (with blade installed): Do not exceed 5 mph (8 km/h), even with the blade up.
Slope Operation Limit (with plow installed): Do not operate on slopes greater than 10°.

Usage Features:

Frame Mounting Bracket Installation: The initial step involves removing a "break-off" portion from the Frame Mounting Bracket, as this piece is only used as a spacer on Honda model 300 ATVs and is not required for the Honda 400. This is a critical step to prevent potential damage to the bike. The bracket is then secured to the ATV frame using two 5/16" U-bolts, with specific holes designated for the Honda 400 model.
Plow Installation: The plow tubes slide into position under the ATV, aligning with 3/8" holes in the frame bracket. Two 3/8" pins with retaining clips secure the plow to the ATV.
Winch Cable Connection: The J-bolt bracket attaches to the plow's cross member. The winch cable, after passing over a roller fairlead, connects to the J-bolt bracket using a 1/4" dia J-bolt. The winch hook should not be removed but simply slid out of the way.
Safety Mechanism (J-bolt): The J-bolt is designed to be a sacrificial component. It breaks the connection between the plow and ATV if the plow encounters high forces, preventing damage to the plow or vehicle. This can occur if the plow is raised too high and stalls, or if the operator attempts to lift too much material.
Operational Guidelines:
- Always read the Plow Operator's Manual and Winch Operator's Manual before use.
- Operate at a walking speed (max 5 mph/8 km/h).
- Plow cautiously to avoid sudden stops or loss of control from impacts with hidden objects.
- Do not operate on steep slopes (over 10°).
- Do not stand or ride on the plow.
- Maintain clear distance from moving parts and joints.
- Keep others away during operation or adjustment.
- Lower the plow to the down position when leaving the ATV unattended.
- If the plow stalls, stop the winch immediately and lower the plow.
- Back up the ATV before raising the plow after pushing material.
- Do not raise the top of the plow blade above the vehicle's headlights.

Maintenance Features:

Pre-Operation Inspection: Before each operation, inspect the plow mechanism, fasteners, cable, and adjustments.
Part Replacement: Replace all worn or damaged parts before operating.
J-bolt Replacement: If the J-bolt breaks, it must be replaced with a spare from the kit. The manual emphasizes that the J-bolt is a critical safety component and its integrity should be maintained.
Roller Fairlead Requirement: A roller fairlead is mandatory when using a winch with this plow to prevent cable damage.
Adjustment for Straightness: If the plow is not straight with respect to the ATV after installation, loosen the nuts on the Frame Mounting Bracket, adjust the plow, and then retighten and torque the nuts to 15 ft-lb (20 N-m).