Download Print this page
Warn 84704 Installation Instructions Manual

Warn 84704 Installation Instructions Manual

Winch mounting kit for honda rancher trx420

Advertisement

Quick Links

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 judg-
ment.
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 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.
not follow recommendations.
This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize
general information worthy of special attention.
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, fire or personal
injury.
Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying
chips can cause eye injury.
Always use extreme caution when cutting and trimming during fitting.
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.
WARN INDUSTRIES
INSTALLATION INSTRUCTIONS
WINCH
Application: Honda Rancher TRX420
CAUTION signals a hazard that may cause minor to moderate injury, if you do
INJURY HAZARD
MOUNTING KIT
Part Number: 84704
WARNING
PAGE 1
84855A2

Advertisement

loading

Summary of Contents for Warn 84704

  • Page 1 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 judg- ment.
  • Page 2: Table Of Contents

    Read installation and operating instructions thoroughly. Before You Begin This kit is compatible with the WARN’s line of ATV winches. Winch is sold separately. Please read WARN’s Winching Technique guide provided with the winch prior to use of this product.
  • Page 3: Parts List

    6mm - 1.00 x 12mm Bolt • Sidecutters or Saw 6.3mm (1/4”) Spacer 8mm-1.25 Lock Nut • Voltmeter or Test Light • 1/4-20 x 1” x 1 3/4” U-bolt Electric Tape 1/4-20 Lock Nut 1/4 Flat Washer WARN INDUSTRIES PAGE 3 84855A2...
  • Page 4: Rancher Trx420 Installation

    (both sides) Figure 2 Remove Front Fascia Remove the four 6mm bolts that secure the front skid plate, figure 3. Save the fasteners as they will be reinstalled later. Remove Figure 3 Front Skid Plate Bolts WARN INDUSTRIES PAGE 4 84855A2...
  • Page 5 Figure 5 Remove Top Bumper Bolts Remove the four remaining bumper bolts that attach the bumper to the vehicle frame, figure 6. Remove the bumper from the vehicle at this time. Remove (both sides) Figure 6 Remove Bumper Bolts WARN INDUSTRIES PAGE 5 84855A2...
  • Page 6 Lock Washers, and Flat Washers neath the bracket. Figure 8 Attach Winch onto Lower Mounting Bracket Place the winch and lower mounting bracket assembly into position in the front bumper, figure 9. Figure 9 Place Winch in Bumper WARN INDUSTRIES PAGE 6 84855A2...
  • Page 7 (B1) and flat washers (B2) into the middle bumper mounting location. Place the supplied spacer (B3) into position between the ATV frame and the winch mounting bracket tab, figure 12. Do not tighten at this time. Figure 12 Bolt and Spacer Location WARN INDUSTRIES PAGE 7 84855A2...
  • Page 8 15. Tighten the motor terminal nuts to the recommended torque of 5.7 N-m (50 lb-in). Slide the motor terminal boots over the motor terminals. Yellow Cable Figure 15 Connect Yellow and Blue Electrical Cables WARN INDUSTRIES PAGE 8 84855A2...
  • Page 9 (both sides) bolts, and the four 6mm bolts to a recommended torque of: 6mm Bolts 6mm bolts - 12 N-m (9 ft-lb) 8mm bolts - 37 N-m (27 ft-lb) Figure 18 Winch and Mount Bolts WARN INDUSTRIES PAGE 9 84855A2...
  • Page 10 6mm bolts removed in step 2 and the four 6mm skid plate bolts removed in step 3. Tighten the 6mm bolts to a recommended torque of 12 N-m (9 ft-lb). Reinstall the two plastic rivets removed in step 1. Figure 21 Front Fascia Reinstalled WARN INDUSTRIES PAGE 10 84855A2...
  • Page 11 Figure 23 Hook Assembly - Assembled Winch and winch mount installation is now com- plete and should look like figure 24. Proceed to section IV, entitled “Winch Wiring”. Figure 24 Winch and Mount Installed WARN INDUSTRIES PAGE 11 84855A2...
  • Page 12: Winch Wiring

    Guide, supplied in the winch kit, for all wiring schematics and specific details on how to wire the winch to the ATV. Black Blue (20 ga.) Green Black Remote optional Yellow Figure 25 Universal Wiring Installation diagram WARN INDUSTRIES PAGE 12 84855A2...
  • Page 13: Trx420 Specific Wiring Instructions

    Guide, supplied in the winch kit, for specific details on how to install the switch onto the ATV. Please note that the switch extension brackets are not used in the TRX420 application. Switch Location Figure 28 Handlebar Switch Location WARN INDUSTRIES PAGE 13 84855A2...
  • Page 14 Route switch leads to the contactor at the rear of the ATV by following the original wiring harnesses along the right side of the frame, figure 31. Existing Harness Figure 31 Switch Lead Routing WARN INDUSTRIES PAGE 14 84855A2...
  • Page 15 31, figure 33, and figure 34. Route Cables Along Frame Tube and Exist- ing Wire Harness Figure 33 Routing Electrical Cables Contactor Route Cables Along Existing Wire Harness Figure 34 Electrical Cables Routing at Contactor WARN INDUSTRIES PAGE 15 84855A2...
  • Page 16 Failure to do so can Figure 37 Main Wire Harness - Right Front Wheel Opening result in product failure which can lead to vehicle damage and operator injury or death. WARN INDUSTRIES PAGE 16 84855A2...
  • Page 17: Maintenance/Care

    Check all moving and rotating parts. Remove debris that may inhibit the part from moving freely. WARNING Failure to perform regular inspections and maintenance on the winch, winch mount, and related hardware may result in vehicle damage and operator injury or death. WARN INDUSTRIES PAGE 17 84855A2...