Warn 81910 - User Manual

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WARN INDUSTRIES PAGE 1 81948A2

WARN® and the WARN logo are trademarks of Warn Industries Inc.

 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 bumper and related hardware.

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

WARNING

INSTALLATION INSTRUCTIONS

BUMPER

Part Number: 81910

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 INSTRUC-

TIONS 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 recom-

mendations.

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.

Applications: 2009+ Honda Rancher

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Summary

General Safety Precautions

Injury Hazard Warnings

Alerts to hazards that could cause serious injury or death if recommendations are not followed.

Moving Parts Entanglement Hazard

Warns about hazards from moving parts that could lead to minor or moderate injury.

Equipment Damage Warnings

Provides notices regarding potential equipment damage if instructions are not followed.

Installation Guide

Top Bumper Mounting

Instructions for loosely fastening the top bumper mounting tab to the vehicle rack.

Bottom Bumper Mounting

Instructions for loosely securing bottom bumper mount tabs to the factory bumper tube.

Final Tightening

Guidance on centering the bumper and tightening all hardware securely.

Maintenance and Care

Part Inspection

Inspect all parts and hardware for rust or deformation prior to each use.

Hardware Tightening

Inspect and tighten all nuts and bolts; replace damaged or loose hardware.

Moving Parts Check

Check all moving or rotating parts for debris that may impede free movement.

Summary

General Safety Precautions

Injury Hazard Warnings

Alerts to hazards that could cause serious injury or death if recommendations are not followed.

Moving Parts Entanglement Hazard

Warns about hazards from moving parts that could lead to minor or moderate injury.

Equipment Damage Warnings

Provides notices regarding potential equipment damage if instructions are not followed.

Installation Guide

Top Bumper Mounting

Instructions for loosely fastening the top bumper mounting tab to the vehicle rack.

Bottom Bumper Mounting

Instructions for loosely securing bottom bumper mount tabs to the factory bumper tube.

Final Tightening

Guidance on centering the bumper and tightening all hardware securely.

Maintenance and Care

Part Inspection

Inspect all parts and hardware for rust or deformation prior to each use.

Hardware Tightening

Inspect and tighten all nuts and bolts; replace damaged or loose hardware.

Moving Parts Check

Check all moving or rotating parts for debris that may impede free movement.

This document provides installation and maintenance instructions for a Warn Industries bumper, part number 81910, designed for 2009+ Honda Rancher models.

Function Description:

The Warn 81910 bumper is an aftermarket accessory designed to be installed on the front of a 2009+ Honda Rancher ATV. Its primary function is to provide protection to the front of the vehicle, potentially enhancing its durability during off-road use or in the event of minor impacts. The bumper also includes integrated mounting holes for additional accessories such as a Warn winch and trail lights, which are sold separately, thereby expanding the vehicle's utility and customization options. The installation process involves securing the bumper to the existing vehicle rack and factory bumper tube using U-bolts, flat washers, and lock nuts.

Important Technical Specifications:

The installation process requires specific fasteners and torque specifications to ensure proper and safe attachment.

Fasteners Used:
- 1/4-20 U-bolts
- 1/4 inch flat washers
- 1/4-20 lock nuts
- 5/16-18 U-bolts
- 5/16 inch flat washers
- 5/16-18 lock nuts
Fastener Torque Specifications:
- 1/4 & M6: 8 lb. ft. (10.8 N-m)
- 5/16 & M8: 17 lb. ft. (12.5 N-m)
- 3/8 & M10: 30 lb. ft. (40.7 N-m)
- 7/16: 50 lb. ft. (67.8 N-m)
- 1/2: 75 lb. ft. (101.7 N-m)
Tools Required for Installation:
- Ratchet
- Sockets: 7/16 and 1/2

Usage Features:

The bumper is designed to integrate with the Honda Rancher's existing structure.

Accessory Integration: It features pre-drilled mounting holes specifically for Warn winches and trail lights, allowing for easy addition of these accessories to enhance the ATV's capabilities for recovery or nighttime operation. These accessories are not included with the bumper and must be purchased separately.
Robust Attachment: The installation method utilizes U-bolts to securely fasten the bumper to both the underside of the vehicle's rack and the lower factory bumper tube, ensuring a stable and durable connection.
Safety Considerations: The manual emphasizes the importance of reading and understanding all safety precautions and operating instructions before installation and operation. It highlights potential hazards such as serious injury or equipment damage from careless installation or operation. Specific warnings include avoiding drilling into fuel lines, brake lines, or electrical wires, wearing safety glasses during drilling, and exercising caution when cutting and trimming. It also warns against operating the product under the influence of drugs or alcohol, or if under 16 years of age.

Maintenance Features:

Regular maintenance is crucial to ensure the continued safe and effective operation of the bumper.

Pre-Use Inspection: Before each use, all parts of the bumper and related hardware should be inspected. Any rusted or deformed hardware must be replaced immediately.
Fastener Inspection and Tightening: All nuts and bolts on the bumper and its associated hardware should be inspected regularly. Any loose fasteners must be tightened to the specified torque. Stripped, fractured, or bent bolts or nuts require immediate replacement. The manual explicitly warns that failure to securely tighten all bolts can lead to product failure, vehicle damage, and operator injury or death.
Moving Parts Check: If the bumper system includes any moving or rotating parts, these should be checked to ensure they move freely and are not inhibited by debris.
Debris Removal: Any debris that may hinder the free movement of parts should be removed.
Regular Inspections: The document stresses the importance of performing regular inspections and maintenance on the bumper and its related hardware, reiterating that failure to do so may result in vehicle damage and operator injury or death.

The document also includes general safety guidelines applicable to any vehicle modification, such as insulating and protecting exposed wiring, installing terminal boots, using appropriate care when lifting components, and ensuring components remain secure during installation and operation. It warns against operating any WARN product with damaged or missing parts.