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Warn 75785 - User Manual

Warn 75785
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©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 76454 A1
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 Sales/Customer Service: 1-503-722-3008
International Fax: 1-503-722-3005
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number: 75785/87686
Application: 2007+ Honda Rancher 420 and 2012 + Honda Foreman
500
GENERAL SAFETY PRECAUTIONS
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
• 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 operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
• Always plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
• Never operate the vehicle on slopes greater than 10 degrees with the plow installed.
• Never stand or ride on the plow.
• Always stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
• 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.
• Always drive slowly over bumpy and rough terrain. Driving at speeds that cause the plow to bounce while in the up position can cause the winch to back-drive, causing the plow to
work its way down. This may result in the plow impacting a stationary object and cause damage to the vehicle and operator injury or death.
• Always drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
• Always be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious damage to the ATV if the plow is raised too high. The
plow blade will drop suddenly if the j-bolt breaks, so always be sure there are no bystanders when you raise and lower the plow.
• Never raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
• Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
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.
Question and Answer IconNeed help?

Do you have a question about the Warn 75785 and is the answer not in the manual?

Summary

General Safety Precautions

Warning: Impact and Moving Parts Entanglement Hazard

Signals a hazard that could cause serious injury or death if recommendations are not followed.

Caution: Injury Hazard

Signals a hazard that may cause minor to moderate injury if recommendations are not followed.

Notice: Mechanical Information

Calls attention to important mechanical information and special notes for emphasis.

Note: General Information Emphasis

Emphasizes general information worthy of special attention.

Caution: Equipment Damage and Operation Hazards

Importance of Reading Instructions

Emphasizes the importance of reading and understanding the installation and operations guide before use.

Age Restriction

Prohibits operation of the product by individuals under 16 years of age.

Operation Under Influence Prohibition

Prohibits operation of the product while under the influence of drugs, alcohol, or medications.

Refer to Winch Kit Guide

Advises referring to the winch kit's Installation and Specification Guide for wiring details.

J-Bolt Overtightening Warning

Warns against overtightening the j-bolt, which can damage the winch cable.

Actuator Cable Routing

Instructs on routing actuator cable through the Termination Bracket slot for proper function and cable life.

Tools and Torque Specifications

Tools Required List

Lists necessary tools for installation, including sockets, wrenches, and drill bits.

Torque Specifications Table

Provides specific torque values (lb. ft. and N-m) for various bolt sizes.

Parts List

Installation Instructions

Step 1: Remove Floorboard Bolts

Remove the two outer M8 floorboard bolts, retaining the nuts for reassembly.

Step 2: Position Spacers

Position the 1/4" spacers (B5) over the floorboard bolt holes.

Step 3: Locate Plow Mount

Loosely secure the plow mount (A1) over the spacers with M8 bolts, washers, and nuts.

Note: Plastic Trimming for 475 cc;500 cc Models

Note: Trimming plastic may be required on 475cc (500) models for correct mount placement.

Step 4: Mark Plow Mount Slots

Center the plow mount and mark the outline and slots onto the plastic skid plate.

Step 5: Remove Plastic Skid Plate

Remove twelve M6 bolts to detach the stock plastic skid plate.

Step 6: Check U-Bolt Position

Reposition plow mount, slide u-bolts around frame tubes and through mounting plate slots.

Step 7: Drill Skid Plate Holes

Mark u-bolt locations on skid plate slots and drill four clearance holes.

Step 8: Install U-Bolts and Fasteners

Loosely fasten skid plate, plow mount, and u-bolts using washers and lock nuts.

Note: Adjusting Skid Plate Holes

Note: Enlarge skid plate holes with a round file if u-bolts do not pass freely.

Step 9: Tighten All Hardware

Tighten all hardware, including skid plate bolts, lock nuts, and M8 bolts/nuts, to specified torque values.

Maintenance and Care

Inspect Metal Parts

Inspect metal parts on plow and mount for rust or deformation, replacing as needed.

Inspect Nuts and Bolts

Check all nuts and bolts for looseness; replace stripped, fractured, or bent ones immediately.

Inspect Cables

Inspect all cables for signs of wear or fraying and replace if necessary.

Inspect Moving Parts

Ensure all moving and rotating parts are clear of debris that could impede movement.

Summary

General Safety Precautions

Warning: Impact and Moving Parts Entanglement Hazard

Signals a hazard that could cause serious injury or death if recommendations are not followed.

Caution: Injury Hazard

Signals a hazard that may cause minor to moderate injury if recommendations are not followed.

Notice: Mechanical Information

Calls attention to important mechanical information and special notes for emphasis.

Note: General Information Emphasis

Emphasizes general information worthy of special attention.

Caution: Equipment Damage and Operation Hazards

Importance of Reading Instructions

Emphasizes the importance of reading and understanding the installation and operations guide before use.

Age Restriction

Prohibits operation of the product by individuals under 16 years of age.

Operation Under Influence Prohibition

Prohibits operation of the product while under the influence of drugs, alcohol, or medications.

Refer to Winch Kit Guide

Advises referring to the winch kit's Installation and Specification Guide for wiring details.

J-Bolt Overtightening Warning

Warns against overtightening the j-bolt, which can damage the winch cable.

Actuator Cable Routing

Instructs on routing actuator cable through the Termination Bracket slot for proper function and cable life.

Tools and Torque Specifications

Tools Required List

Lists necessary tools for installation, including sockets, wrenches, and drill bits.

Torque Specifications Table

Provides specific torque values (lb. ft. and N-m) for various bolt sizes.

Parts List

Installation Instructions

Step 1: Remove Floorboard Bolts

Remove the two outer M8 floorboard bolts, retaining the nuts for reassembly.

Step 2: Position Spacers

Position the 1/4" spacers (B5) over the floorboard bolt holes.

Step 3: Locate Plow Mount

Loosely secure the plow mount (A1) over the spacers with M8 bolts, washers, and nuts.

Note: Plastic Trimming for 475 cc;500 cc Models

Note: Trimming plastic may be required on 475cc (500) models for correct mount placement.

Step 4: Mark Plow Mount Slots

Center the plow mount and mark the outline and slots onto the plastic skid plate.

Step 5: Remove Plastic Skid Plate

Remove twelve M6 bolts to detach the stock plastic skid plate.

Step 6: Check U-Bolt Position

Reposition plow mount, slide u-bolts around frame tubes and through mounting plate slots.

Step 7: Drill Skid Plate Holes

Mark u-bolt locations on skid plate slots and drill four clearance holes.

Step 8: Install U-Bolts and Fasteners

Loosely fasten skid plate, plow mount, and u-bolts using washers and lock nuts.

Note: Adjusting Skid Plate Holes

Note: Enlarge skid plate holes with a round file if u-bolts do not pass freely.

Step 9: Tighten All Hardware

Tighten all hardware, including skid plate bolts, lock nuts, and M8 bolts/nuts, to specified torque values.

Maintenance and Care

Inspect Metal Parts

Inspect metal parts on plow and mount for rust or deformation, replacing as needed.

Inspect Nuts and Bolts

Check all nuts and bolts for looseness; replace stripped, fractured, or bent ones immediately.

Inspect Cables

Inspect all cables for signs of wear or fraying and replace if necessary.

Inspect Moving Parts

Ensure all moving and rotating parts are clear of debris that could impede movement.

Warn 75785 Specifications

General IconGeneral
BrandWarn
Model75785
CategorySnow Blower Accessories
LanguageEnglish