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WARN INDUSTRIES 

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                   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, 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.

 

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 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.   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.

Summary of Contents for 84705

Page 1: ...ly 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 WAR...

Page 2: ...operate this product if you are under 16 years of age Never operate this product when under the influence of drugs alcohol or medications Read installation and operating instructions thoroughly Notic...

Page 3: ...red Ratchet Sockets 10mm 12mm 7 16 1 2 9 16 Wrenches 1 2 9 16 Drill 1 4 drill bit I Parts List Ref Description Qty A1 Mounting Plate 1 B1 1 4 20 x 1 x 1 1 2 U bolt 2 B2 1 4 flat washer 4 B3 1 4 20 loc...

Page 4: ...f the front plastic fascia figure 2 Use a large screw driver to carefully remove the center rivet After removing the center rivet remove the rivet housing Save the fasteners as they will be used to re...

Page 5: ...ic headlight assembly figure 4 Save the fasteners as they will be used to reinstall the front bumper 5 Remove the two top 8mm bumper bolts that attach the front bumper to the front rack figure 5 Save...

Page 6: ...d lock washers provided with the winch as shown in figure 8 Tighten the two 3 8 dia bolts to a recommended torque of 34 N m 25 ft lb Note At this point in the installation refer to the Mo tor Rotation...

Page 7: ...acket tab figure 11 Do not tighten at this time 13 Reinstall the two 6mm bolts that were removed in step 4 Reinstall the four rivet fasteners that were removed in step 2 Reinstall the two 6mm bolts th...

Page 8: ...e winch cable through the roller fairlead Attach the clevis hook supplied with the winch to the end cable loop as shown in figure 12 This is done by placing the winch wire loop between clevis pin tabs...

Page 9: ...and Specification Guide supplied in the winch kit for all wiring schematics and specific details on how to wire the winch to the ATV Notice Figure 15 Universal Wiring Installation diagram Blue 6 ga R...

Page 10: ...to remove the 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 It should be noted that the following instru...

Page 11: ...2 Handlebar Switch Installation Step Four in the Installation and Specification Guide a Before installing the winch switch route the red wire towards the switch case Secure with electrical tape a dis...

Page 12: ...ire only has power when the key switch is on Trim the red switch wire excess approximately 20cm 8 in Retape with electrical tape d Remove the left and right side panels by removing the fasteners holdi...

Page 13: ...e 15 figure 19 figure 20 and figure 26 Route the winch wires yellow and blue from the contactor to the front of the ATV figure 28 The routing should follow along the right side frame tube to the front...

Page 14: ...ery electrical cables red and black from the contactor to the battery along the outside of the ATV frame as seen in figure 26 There is a hole in the battery compartment that the electrical cables can...

Page 15: ...nstall the seat VI Maintenance Care Inspect all metal parts on the winch winch mount and related hardware Replace all that appears rusted cracked or deformed prior to use Inspect all nuts and bolts on...

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