Warn 84705 - User Manual

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WARN INDUSTRIES PAGE 1 84856A0

 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 winch, winch mount and related hardware.

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

WARNING

INSTALLATION INSTRUCTIONS

WINCH MOUNTING KIT

Part Number: 84705

Application: Honda Foreman 500 & Honda Rubicon

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

Rubicon & Foreman Installation

Rubicon & Foreman Specific Wiring Instructions

Contactor Location

Locate and position the contactor on the right rear inner fender, near the rear tool box, securing with bolts.

Handlebar Switch Installation

Mount the winch switch on the left handlebars, connect wires to ignition harness and route to contactor.

Wiring Installation

Connect electrical cables to contactor and winch motor, route battery cables to battery, secure all wiring.

Summary

Rubicon & Foreman Installation

Rubicon & Foreman Specific Wiring Instructions

Contactor Location

Locate and position the contactor on the right rear inner fender, near the rear tool box, securing with bolts.

Handlebar Switch Installation

Mount the winch switch on the left handlebars, connect wires to ignition harness and route to contactor.

Wiring Installation

Connect electrical cables to contactor and winch motor, route battery cables to battery, secure all wiring.

This document provides installation instructions for the WARN Winch Mounting Kit, part number 84705, designed for Honda Foreman 500 and Honda Rubicon ATVs. The kit facilitates the integration of a WARN ATV winch (sold separately) onto the vehicle, enabling recovery and utility functions.

Function Description:

The WARN Winch Mounting Kit serves as a robust interface between a WARN ATV winch and the front frame of specific Honda ATV models. Its primary function is to securely attach the winch and its associated components, such as the roller fairlead, to the vehicle. This allows the winch to be used for various tasks, including vehicle recovery, pulling, and other utility applications. The installation process involves removing several front-end components of the ATV, installing the mounting plate and winch, and then reassembling the vehicle's front end. The kit also includes specific wiring instructions tailored to the Honda Foreman 500 and Rubicon, ensuring proper electrical connection and operation of the winch.

Important Technical Specifications:

The kit itself is a mounting solution, and its technical specifications primarily relate to the fasteners and torque values required for installation.

Mounting Plate (A1): One mounting plate is included.
U-bolts (B1): Two 1/4-20 x 1" x 1 1/2" U-bolts are used for securing the winch assembly to the front bumper.
Flat Washers (B2): Four 1/4" flat washers are provided.
Lock Nuts (B3): Four 1/4-20 lock nuts are used with the U-bolts.
Bolts (B4): Two 8mm-1.25 x 25mm bolts are used for middle bumper mounting.
Spacers (B5): Two spacers are included for the middle bumper mounting.
Recommended Torque Values:
- 3/8" dia bolts (for roller fairlead): 34 N-m (25 ft-lb)
- 5/16" dia bolts (for winch to mounting bracket): 17 N-m (12 ft-lb)
- 1/4" U-bolts (for winch assembly to front bumper): 10 N-m (7 ft-lb)
- 6mm bolts: 12 N-m (9 ft-lb)
- 8mm bolts: 37 N-m (27 ft-lb)
- 1/4-20 x 1" bolts (for contactor): 7 N-m (5 ft-lb)
Winch Compatibility: Compatible with WARN's line of ATV winches, specifically a 2.5ci winch is mentioned in the instructions.
Electrical Cable Gauges (Winch Wiring - Universal Diagram):
- Blue: 6 ga.
- Yellow: 6 ga.
- Black (winch motor): 6 ga.
- Red (winch motor): 6 ga.
- Red (battery): 20 ga.
- Green (contactor to switch): Not specified, but implied to be smaller gauge.
- Black (contactor to switch): Not specified, but implied to be smaller gauge.

Usage Features:

The kit itself is not a functional device but enables the use of a WARN ATV winch. Key usage features facilitated by the kit include:

Secure Winch Mounting: Provides a stable and durable platform for mounting the winch, ensuring it can withstand the forces generated during winching operations.
Integrated Fairlead Attachment: Allows for the secure attachment of a roller fairlead, which guides the winch cable and reduces wear.
Optimized Winch Motor Orientation: Instructions guide the user to rotate the winch motor to a horizontal position, preventing interference with the headlight cowling.
Vehicle-Specific Wiring Guidance: Offers detailed, ATV-specific instructions for routing and connecting the winch's electrical components, including the contactor, handlebar switch, and battery connections. This ensures a clean, safe, and functional electrical installation that avoids moving parts, hot components, and pinching hazards.
Clevis Hook Attachment: Instructions detail the proper method for attaching the clevis hook to the winch cable, ensuring a secure connection for recovery operations.
Compatibility with WARN ATV Winches: Designed to work seamlessly with WARN's range of ATV winches, ensuring proper fit and function.

Maintenance Features:

The document emphasizes the importance of regular maintenance for the winch, winch mount, and related hardware to ensure safety and longevity.

Regular Inspections: Users are instructed to perform regular inspections of all metal parts on the winch, winch mount, and related hardware for rust, cracks, or deformation. Any damaged parts should be replaced prior to use.
Fastener Checks: All nuts and bolts on the winch, winch mount, and associated hardware must be inspected and tightened securely before each use. Loose, stripped, fractured, or bent fasteners require immediate replacement.
Cable Integrity: Winch cables should be checked for wear or fraying, and damaged cables must be replaced.
Clearance of Moving Parts: All moving and rotating parts should be checked to ensure they move freely and are not inhibited by debris.
Electrical System Integrity: While not explicitly listed under maintenance, the detailed wiring instructions imply that the electrical connections should be periodically checked for insulation integrity, secure terminals, and proper routing to prevent damage or short circuits. The use of terminal boots is also highlighted for protection.

The installation process is comprehensive, starting with the removal of various front-end components like the skid plate, plastic fascia, and bumper. The mounting plate and winch are then installed, followed by the reassembly of the vehicle's components. Special attention is given to the electrical wiring, with detailed steps for locating the contactor, installing the handlebar switch, and routing all electrical cables to avoid potential hazards. The document stresses the importance of safety throughout the installation and operation, with clear warnings about potential injury and equipment damage if instructions are not followed.