Warn 37852 - User Manual

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WARN INDUSTRIES PAGE 1 39526 Rev B1

INSTALLATION INSTRUCTIONS

ATV SNOW PLOW

Mounting Kit: PN 37852

Application: HONDA MODELS: 450S AND

450ES

WARNING

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

• Always read the Plow Operator’s Manual, the Winch Operator’s Manual, and all warning labels

before operating or using your ATV plow.

• Always operate ATV at a walking speed with the blade installed. Do Not exceed 5mph (8 km/h)

even with the blade up.

• Always plow CAUTIOUSLY, impact with a hidden or stationary object may cause the ATV to

stop suddenly or go out of control.

• Never operate the ATV on slopes greater than 10° with the plow installed.

• Never stand or ride on the plow.

• Always stay clear of moving parts and joints. Keep others away when operating or adjusting

plow.

• Always inspect the plow mechanism, fasteners, cable, and adjustments before operating. Replace

all worn or damaged parts before operating.

• Always 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)

Drill (for 450ES only)

3/8” Drill Bit (for 450ES only)

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

Frame Mounting Bracket Installation

Installing U-Bolts Onto Frame

Details on how to install U-bolts onto the ATV frame for the mounting bracket.

Frame Mounting Hole Locations

Diagram showing specific hole locations for frame mounting on different ATV models.

Plow Installation

Frame Mount Installation

Procedure for sliding and securing the plow assembly to the frame.

J-Bolt Bracket

Instructions for attaching the J-bolt bracket to the plow cross member.

J-Bolt and Winch Cable

Guidance on connecting the winch cable to the J-bolt bracket.

Summary

Frame Mounting Bracket Installation

Installing U-Bolts Onto Frame

Details on how to install U-bolts onto the ATV frame for the mounting bracket.

Frame Mounting Hole Locations

Diagram showing specific hole locations for frame mounting on different ATV models.

Plow Installation

Frame Mount Installation

Procedure for sliding and securing the plow assembly to the frame.

J-Bolt Bracket

Instructions for attaching the J-bolt bracket to the plow cross member.

J-Bolt and Winch Cable

Guidance on connecting the winch cable to the J-bolt bracket.

This document provides installation instructions and safety information for the WARN ATV Snow Plow, specifically designed for Honda 450S and 450ES models. The mounting kit for this plow is PN 37852.

Function Description:

The WARN ATV Snow Plow is an accessory designed to be attached to Honda 450S and 450ES ATVs for snow removal. It allows the ATV to push snow, making it a useful tool for clearing driveways, paths, and other areas. The system includes a frame mounting bracket that attaches to the ATV's frame, and a plow assembly that connects to this bracket. A winch (not included, but required for operation) is used to lift and lower the plow blade. The J-bolt mechanism is a critical safety feature, designed to break the connection between the plow and the ATV under high forces to prevent damage to the plow or vehicle.

Important Technical Specifications:

Mounting Kit PN: 37852
Application: Honda 450S and 450ES models
Fastener Torques:
- 5/16" Nylock nuts on U-bolts: Approximately 15 ft-lb (20 N-m)
- 3/8" bolt and nylock nut for J-bolt bracket: 20 ft-lb (28 N-m)
Plow Speed Limit: Do not exceed 5 mph (8 km/h) with the blade installed, even when raised.
Slope Limit: Never operate the ATV on slopes greater than 10° with the plow installed.
Winch Requirement: A winch is required for lifting and lowering the plow. A roller fairlead must be used to prevent cable damage.
J-Bolt: A 1/4" diameter J-bolt is used to connect the winch cable to the plow. This J-bolt is designed as a shear pin to break under excessive load, protecting the ATV and plow. Spare hardware for the J-bolt is included in the kit.

Usage Features:

Installation Process:
1. Frame Mounting Bracket Preparation: Before installation, a "break-off" portion of the frame mounting bracket must be removed. This piece is only used as a spacer for Honda 300 models and is not needed for the 450 application. Failure to remove it can cause damage to the bike if it snags on the ground.
2. Frame Mounting Bracket Installation: The bracket is raised into position under the ATV frame. U-bolts are used to secure it. For 450S models, two 5/16" U-bolts are installed. For 450ES models, one U-bolt is installed, and a hole must be drilled through the skid plate using the bracket as a template to install the second U-bolt. The "tabs" on the bracket should face the front of the bike.
3. Plow Installation: The plow assembly slides under the ATV, and its tube wings align with 3/8" holes in the frame bracket. 3/8" pins with retaining clips secure the plow to the ATV. If the plow is not straight, the nuts on the frame mounting bracket can be loosened, adjustments made, and then retightened.
4. J-Bolt Bracket Attachment: The J-bolt bracket attaches to the center hole of the plow cross member using a 3/8" x 1" bolt and a 3/8" nylock nut. The bracket's side flanges should be parallel to the ground.
5. Winch Cable Connection: The winch cable runs over the roller fairlead and connects to the J-bolt bracket using a 1/4" J-bolt. The loop on the winch cable hooks onto the J-bolt, which then slides into a slotted hole in the J-bracket and is secured with a 1/4" nylock nut. The winch hook should not be removed but simply slid out of the way.
Safety Precautions:
- Always read the Plow Operator's Manual and Winch Operator's Manual, along with all warning labels, before operation.
- Operate the ATV at a walking speed (max 5 mph/8 km/h) with the blade installed.
- Plow cautiously; impacts with hidden objects can cause sudden stops or loss of control.
- Avoid operating on slopes greater than 10°.
- Never stand or ride on the plow.
- Keep clear of moving parts and joints. Ensure others are also clear.
- Always inspect the plow mechanism, fasteners, cable, and adjustments before each use. Replace worn or damaged parts.
- Lower the plow to the down position before leaving the ATV unattended.
- The J-bolt is a critical safety component. It is designed to break if the plow is raised too high, stalls, or attempts to lift too much material, preventing damage to the ATV or plow. Do not raise the top of the plow blade above the vehicle's headlights. If the plow stalls, stop the winch immediately and lower the plow. Back up the ATV before raising the plow after pushing material.
- A roller fairlead is mandatory when using a winch to prevent cable damage.

Maintenance Features:

Regular Inspection: Always inspect the plow mechanism, fasteners, cable, and adjustments before operating.
Part Replacement: Replace all worn or damaged parts before operating.
J-Bolt Replacement: If the J-bolt breaks, replace it with the spare hardware provided in the kit.
Warranty: Warn Industries offers a limited one (1) year warranty on mechanical and electrical components of their products, covering defects in material and workmanship from the original purchase date. The warranty requires proof of purchase and applies only to the original purchaser. It does not cover damage from accident, abuse, misuse, modification, improper installation, or commercial/industrial use. The warranty explicitly excludes finish and wire rope for winches, and finish for various other components.