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Warn 84705 Installation Instructions Manual

Warn 84705 Installation Instructions Manual

Winch mounting kit

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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.
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 MOUNTING KIT
Application: Honda Foreman 500 & Honda Rubicon
CAUTION signals a hazard that may cause minor to moderate injury, if you do
INJURY HAZARD
PAGE 1
Part Number: 84705
WARNING
84856A0

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Summary of Contents for Warn 84705

  • 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 judgment.
  • Page 2: Table Of Contents

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

    • Sockets: 10mm, 12mm, 7/16”, 1/2”, 9/16” • Wrenches: 1/2”, 9/16” 1/4-20 x 1” x 1 1/2” U-bolt • Drill 1/4” flat washer 1/4-20 lock nut • 1/4” drill bit 8mm-1.25 x 25mm bolt Spacer WARN INDUSTRIES PAGE 3 84856A0...
  • Page 4: Rubicon & Foreman Installation

    Remove (both sides) Figure 2 Remove the Four Plastic Rivets Remove the two 6mm bolts that attach the front plastic fascia to the bumper, figure 3. Remove the front plastic fascia at this time. Remove (both sides) Figure 3 Front Plastic Fascia Bolts WARN INDUSTRIES PAGE 4 84856A0...
  • Page 5 Figure 5 Remove Top Bumper Bolts Remove the two bottom bumper bolts that attach the bumper to the bottom of the vehicle frame, figure 6. Save the fasteners as they will be used to reinstall the front bumper. Remove Figure 6 Remove Bottom Bumper Bolts WARN INDUSTRIES PAGE 5 84856A0...
  • Page 6 5/16” dia bolts and lock washers supplied with the winch kit. Mount the winch so that the motor faces the right side of the vehicle, figure 9. Tighten the bolts to a recommended torque of 17 N-m (12 ft-lb). Figure 9 Install Winch onto Mounting Bracket and Fairlead Bracket WARN INDUSTRIES PAGE 6 84856A0...
  • Page 7 37 N-m (27 ft-lb) 15. Tighten all fasteners to a recommended torque of: Clevis Hook 6mm Bolts 6mm bolts - 12 N-m (9 ft-lb) 12 N-m (9 ft-lb) 8mm bolts - 37 N-m (27 ft-lb) Figure 12 Completed Winch Installation on the Rubicon 1/4” U-bolts - 10 N-m (7 ft-lb) WARN INDUSTRIES PAGE 7 84856A0...
  • Page 8 IV, entitled “Winch Wiring”. WARNING Tighten all nuts and bolts securely. Failure to check all nuts and bolts prior to use can result in product failure which can lead to vehicle damage and operator injury or death. Figure 14 Hook Assembly - Assembled WARN INDUSTRIES PAGE 8 84856A0...
  • Page 9: Winch Wiring

    Guide, supplied in the winch kit, for all wiring schematics and specific details on how to wire the winch to the ATV. Blue (6 ga.) (20 ga.) Black (6 ga.) Green Black (Remote optional for (6 ga.) 2.5ci) Yellow (6 ga.) Figure 15 Universal Wiring Installation diagram WARN INDUSTRIES PAGE 9 84856A0...
  • Page 10: Rubicon & Foreman Specific Wiring Instructions

    Remove Wire Harness Bracket Figure 17 Remove Wire Harness Bracket d. Relocate the wire harness that was removed along the rear rack tube, figure 18. Use a zip-tie to secure the wire harness. Rear Rack Tube Secure Wire Harness with Zip-Tie Figure 18 Contactor Location - Right Side of Tool Box WARN INDUSTRIES PAGE 10 84856A0...
  • Page 11 21. This will allow you to see the red wire when routing the switch wires, down the steering column, to the contactor. Secure a distance of 25cm Red Wire (10in) from this point Secure with Electrical Tape Figure 21 Red Wire - Tie-off 25cm (10in) WARN INDUSTRIES PAGE 11 84856A0...
  • Page 12 20cm (8 in). Retape with electrical Ignition Switch Wire tape. Harness Figure 23 Connecting Switch - Red Wire d. Remove the left and right side panels by removing the fasteners holding them in place, figure 24. Keep these fasteners for reinstallation. Right Side Panels Figure 24 Remove Side Panels WARN INDUSTRIES PAGE 12 84856A0...
  • Page 13 Use cable ties to secure all electrical cables to the ATV frame. Avoid all moving Figure 26 Routing Electrical Cables and potentially hot components of the ATV when routing the electrical cables. Note: It may be necessary to remove or loosen the front plastic fascia to gain enough access to the motor terminal. WARN INDUSTRIES PAGE 13 84856A0...
  • Page 14 ATV frame. Avoid all moving and potentially hot components of the ATV when routing the electrical cables. Avoid areas where the wiring could be pinched when components are reinstalled (such as the seat). Figure 29 Electrical Connection - Battery Connection WARN INDUSTRIES PAGE 14 84856A0...
  • Page 15: 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 hard- ware may result in vehicle damage and operator injury or death. WARN INDUSTRIES PAGE 15 84856A0...