trx420 winch kit installation...
TRANSCRIPT
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 1 of 16
PARTS LIST
Accessory Application Publications No.
Issue Date
Honda Dealer: Please give a copy of these instructions to your customer.
INSTALLATIONINSTRUCTIONS
Accessory WeightWINCH KIT
P/N 08L94-HP5-100
TRX420 (All)
Revised September2010
No. Description Qty
(1) Upper mounting bracket 1
(2) Lower mounting bracket 1
(3) Side mounting bracket 1
(4) 8 x 30 mm bolt 4
(5) 8 mm flat washer 8
(6) 9.5 mm spacer 2
(7) 6 x 12 mm flange bolt 2
(8) 6.3 mm spacer 1
(9) 8 mm lock nut 1
(10) Battery cable (Red) 1
(11) Battery cable (Black) 1
(12) Power cable (Yellow) 1
(13) Power cable (Blue) 1
(14) Wire tie 12
(15) Terminal boot 6
(16) Switch bracket 1
(17) 3 mm screw w/ stopper washer 2
(18) Holder 2
(19) 5 mm nut 2
(20) Stopper washer (large) 2
(21) 5 mm socket bolt (1 long and 1 short) 2
(22) 6 mm U-bolt 2
(23) 6 mm lock nut 4
(24) 6 mm flat washer 4
(4)(5)(6)
(7)
(13) (12) (10)(11) (15)
(14)
(17)
(16)
(19)(20)
(18)
(21)
(22)
(24)(23)
MII 13032
35 lbs (16 kg)
(1)
(2)
(9)
(3)
(8)
2 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.
CUSTOMER INFORMATION:The information in this installation instruction is intendedfor use only by skilled technicians who have the propertools, equipment, and training to correctly and safely addequipment to your ATV. These procedures should not beattempted by “Do-It-Yourselfers”.
BEFORE YOU BEGINThis kit includes a WARN ATV winch. Please read WARN’sWinching Technique guide provided with the winch priorto use of this product.
No. Description Qty
(1) Roller fairlead 1
(2) 10 mm nut 2
(3) 10 mm washer 2
(4) 10 mm spring washer 2
(5) 10 mm bolt 2
(6) Winch 1
(7) 8 x 20 mm Winch bolt 4
(8) Spring washer 4
(9) 8 mm Winch flat washer 4
(10) Orange pull strap 1
(11) Hook 1
(12) Clevis pin 1
(13) Cotter pin 1
(14) Winch nut 2
(15) Switch 1
(16) Contactor 1
(17) Contactor nut 8
(18) 6mm Spring washer 8
(5)
(17)
(9)
(16)
(8)
(7)
(14)
(6)
(1) (4)
(3)
(2)
(13)
(10)
(11)(12)
(15)
WINCH KIT
TORQUE CHARTTighten all screws, bolts, and nuts to their specified torquevalues. Refer to the Service Manual for the torque valuesof the removed parts.
TOOLS AND SUPPLIES REQUIREDSocket (10 mm, 12 mm, 13 mm, 17 mm, 7/16 in)RachetBox-end wrench (10 mm, 13 mm, 14 mm, 17 mm, 3/8 in,7/16 in)Phillips ® screwdriverAllen wrenches (1/8 in, 5 mm)Side-cutters or SawVoltmeter or test lightElectrical tapeScissorsTorque wrench
Item N·m kgf·m Ibf·ft
5 mm nut 5 0.5 3.6
6 mm bolt 12 1.2 9
6.3 mm bolt 7 0.7 5
6.3 mm lock nut 7 0.7 5
8 mm bolt 37 3.7 27
8 mm lock nut 37 3.7 27
10 mm nut 34 3.5 25
(18)
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 3 of 16
INSTALLATIONNOTES:
• Disconnect the negative cable from the battery beforeinstalling this accessory.
• The memories of the tripmeter and clock will be erasedwhen you disconnect the battery. Reset the clock afterreconnecting the battery.
• Trim the excess ends off the wire ties after attachingthem to the wire harnesses. Do not allow the cut partof the wire tie to interfere with another harness orbrake hose.
REAR COVER
RIGHT AND LEFTTANK SIDE COVER
SEAT
2. Remove the parts, and disconnect the negativeterminal of the battery.
1. Allow the engine and exhaust system to cool beforeinstalling this accessory.
USE AND CARE INFORMATION• Inspect all metal parts on the winch, winch mount and
related hardware. Replace all parts that appear rusted,cracked, or deformed prior to use.
• Inspect all nuts and bolts on the winch, winch mount,and related hardware prior to each use. Tighten allnuts and bolts that are loose. Missing, stripped,fractured, or bent bolts or nuts need to be replacedimmediately.
• Subtract the weight of this accessory (35 lbs) fromthe front cargo rack weight limit (66 lbs). Do not loadmore than 31 lbs. of cargo on the front rack.
• Check all cables prior to use. Replace cables thatare worn or frayed.
• Check all moving and rotating parts. Remove debristhat may inhibit the free movement of any parts.
Winch Capacity 4000 lbs
NOTICEFailure to perform regular inspections and maintenanceon the winch, winch mount, and related hardware mayresult in vehicle damage.
SAFETYWhen installing your ATV winch system, read and followall mounting and safety instructions. Always use cautionwhen working with electricity and verify that there are noexposed electrical connections before energizing yourwinch circuit. For specifications and performance data,refer to the specification sheet supplied with your winch.
4 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.
3. Remove the side covers as shown.
LEFT SIDE COVER
RIGHT SIDE COVER
BOLT
BOLT
CLIP
7. Remove the fuel tank cap as shown.
HOSEPull out.
5. Remove the indicated nuts.
NUT
6. Disconnect the connector as shown.
CONNECTOR
METERLay back againstthe fuel tank cover.
4. Remove the hose as shown.
FUEL TANK CAPRemove.
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 5 of 16
8. Remove the six trim clips and tank cover as shown.
CLIP
TANK COVER
9. Install the fuel tank cap as shown.
FUEL TANK CAP
10. Remove the indicated clips from the left radiator grillcover.
11. Remove the indicated connector.
3-PIN CONNECTOR (Black)Remove.
CLIP
CLIP
CLIP
12. Remove the left radiator grille cover as shown.
LEFT RADIATORGRILLE COVER
13. Remove the right radiator grille cover in the samemanner.
6 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.
14. Assemble the switch as shown.3 mm SCREW
STOPPERWASHER (small)
SWITCH BRACKET
SWITCH
15. Loosely install the holder as shown.
5 mm NUT
HOLDER
HOLDER
5 mm SOCKET BOLT(SHORT)
5 mm NUT
STOPPERWASHER (large)
5 mm SOCKETBOLT (LONG)
SWITCH
17. Route the switch harness as shown.
SWITCH HARNESS
CLAMPRoute the harnessthrough the clamp.
SWITCH HARNESS
WIRE TIE (Reuse)Secure to thevehicle’s harness.
16. Install the switch as shown.• Tighten the upper bolt first, then tighten the
lower bolt.
SWITCH HARNESS
18. Route the switch harness as shown.
WIRE TIE (Reuse)Secure to the handlebar togetherwith the vehicle’s harness.
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 7 of 16
19. Route the bullet connector side of the switch harnessto the rear as shown.
SWITCH HARNESS
SWITCH HARNESS
22. Pass battery cable through the terminal boot asshown.• Repeat on the battery cable (red).
23. Install terminal boots at both ends of each power cableas shown.
BULLET CONNECTORS
20. Locate the accessory socket on the right radiator grilland remove the cap as shown. Route the 2P whiteconnector end of the switch harness toward thesocket.
ACCESSORY SOCKET
CAPRemove.
POWER CABLE(Yellow and Blue)
TERMINAL BOOT
BATTERY CABLE (Black)
TERMINAL BOOT
21. Insert the cap into the 2P White connector and connectthe switch harness to the accessory socket as shown.Bundle any excess wire with a wire tie.
2P WHITECONNECTOR
ACCESSORYSOCKET (Black)
CAPInsert.
SWITCH HARNESS
SWITCH HARNESS
8 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.
24. Loosely install the contactor to the frame as shown.
CONTACTOR
1/4-20 in LOCK NUT
1/4 in FLATWASHER
U-BOLT
25. Connect the battery cables to the corresponding colorterminals on the contactor as shown.
BATTERY CABLE (Red)
BATTERYCABLE (Black)
BATTERY CABLE (Red)
BATTERY CABLE (Black)
Top view
CONTACTOR
26. Route the battery cables as shown.
FRONT
6 mm NUT
RED
BLUE BLACK
YELLOW
FUSE BOX
6 mm SPRINGWASHER
27. Connect the power cables to the corresponding colorterminals on the contactor as shown..
POWER CABLE (Blue)6 mm NUT
6 mm SPRINGWASHER
POWER CABLE(Yellow)
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 9 of 16
TERMINAL BOOTCover the connectors.
TERMINAL BOOTCover the connectors.
28. Cover each cable connector with the terminal bootas shown.
29. Connect the contactor harness as shown.
SWITCH HARNESS
CONTACTORHARNESS
CONTACTORPush down the connectedcontactor harness towardthe rear to store it.
30. Rotate the contactor towards the rear as shown andsecure it.• Tighten the 6 mm lock nuts as shown.
6 mm LOCK NUTS
Adjust so that it becomes horizontal.
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WIRE TIE (Reuse)Secure both cables.
RIBSecure each cable.
31. Route each power cable as shown. 33. Route the power cables as shown.
32. Route each power cable as shown.
POWER CABLE (Blue)Route along thevehicle’s harness.
POWER CABLE (Yellow)Route along thevehicle’s harness.
POWER CABLE(Blue)
POWER CABLE(Yellow)
SWITCH HARNESS
34. Remove the clips, bolts, and front pipe guardas shown.
CLIP CLIP
SWITCH HARNESSRoute along the vehicle’s harness.
FRONT PIPEGUARD
FLANGE BOLT FLANGE BOLT
RIBSecure each cable.
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 11 of 16
35. Remove the indicated bolts.
FLANGE BOLTFLANGE BOLT
FLANGE BOLT
WASHER
SKID PLATE
POWER CABLE (Blue)
POWER CABLE (Yellow)
37. Route the power cable as shown.
POWER CABLE(Blue)
POWER CABLE(Yellow)
36. Lower the skid plate as shown.
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38. Route the power cables as shown.
POWER CABLE (Blue)
POWER CABLE (Yellow)
SKID PLATE
SKID PLATE
BOLT
41. Remove the bolts front carrier pipe as shown.
FRONTCARRIER PIPE
BOLT
BOLT(Save)
BOLT(Save)
40. Remove the indicated bolts as shown.• Repeat on the right side.
39. Cut off at the indicated portion of the skidplateas shown.• After cutting, remove any burrs.
POWER CABLE(Blue)
POWER CABLE (Yellow)
SIDE CUTTERSCut out.
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 13 of 16
42. Remove the radiator grille under cover as shown.
RADIATOR GRILLEUNDER COVER
43. Assemble the lower mounting bracket as shown.6 x 12 mmFLANGE BOLT
LOWERMOUNTINGBRACKET
SIDEMOUNTINGBRACKET
44. Remove the shipping screw and loosely install theassembled lower mounting bracket onto the winchas shown. 8 x 20 mm BOLT
8 mm FLAT WASHER
SPRING WASHER
LOWER MOUNTINGBRACKET ASSEMBLY
WINCH
WINCH
FRONT CARRIER PIPE
WINCH
45. Place the preassembled winch onto the front carrierpipe at the shown position.
FRONTCARRIER PIPE
SHIPPING SCREW
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8 x 30 mmBOLT
FRONT CARRIER PIPE
6.3 mmSPACER
47. Install the upper mounting bracket as shown.
8 x 20 mmBOLT
SPRINGWASHER
9.5 mm SPACER
46. With the winch set, loosely install the front carrier pipeas shown.• Perform this work with two people and support
the winch so that it does not drop down.
8 x 30 mmBOLT 8 mm LOCK NUT
Install the 9.5 mm spacer between frame and uppermounting bracket.• Do the same also on the right side.
8 x 30 mmBOLT
48. Install the roller fairlead as shown.
10 mm SPRING WASHER
10 mm BOLT
10 mm NUTROLLERFAIRLEAD
BOLT
FRONT CARRIER PIPE
8 mm FLATWASHER
8 mm FLATWASHER
8 mm FLATWASHER
8 mm FLAT WASHER
< Upper view >
< Lower view >
ROLLERFAIRLEAD
UPPER MOUNTINGBRACKET
© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 15 of 16
FLANGE NUT POWER CABLE (Blue)
WINCH
51. Connect the yellow power cable as shown.• After connection, cover the cable terminal with
the terminal boot to prevent contact with theframe.
FLANGE NUT
WINCH
49. Install the hook as shown.
COTTER PIN
CLEVIS PIN
ORANGE PULLSTRAP
HOOK
50. Secure the power cables as shown and connect theblue power cable.• After connection, cover the cable terminal with
the terminal boot to prevent contact with theframe.
TERMINAL (Blue)
WIRE TIESecure the powercables to the frame.
POWER CABLE (Yellow)
POWERCABLE (Yellow)
TERMINAL(Yellow)
COTTER PIN
CLEVIS PIN
16 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.
CHECK THE SYSTEM:54. Before using the winch, verify the following:
• The wiring to all components is correct. All loose wiresare wrapped tight using cable-ties.
• There are no exposed wires or terminals. Cover anyexposed wires or terminals with terminal boots, heatshrink tubing, or electricians tape.
• Turn the ATV ignition switch to the ON position.• Check the winch for proper operation. The wire rope
should spool in and out in the direction indicated onthe switch.
SCISSORS
BATTERY COVER
NEGATIVE (-) TERMINAL BATTERY BOLT(Reuse)
POSITIVE (+) TERMINAL
53. Connec t t he b lack ba t te ry cab le to thenegative (-) battery terminal as shown.
55. Install the vehicle’s parts in the reverse order ofremoval.
Cut the positive (+) battery terminal cover as shown.
BATTERY CABLE (Red)
BATTERY CABLE (Black)
BATTERY BOLT (Reuse)
52. Connect the red battery cable to the positive (+)battery terminal as shown.• After connecting, Cover the connectors.