Warn 83405 Manuale utente
PAGE1 83406A0
INJURYHAZARD
Failuretoobservetheseinstructionscouldleadtosevereinjuryordeath.
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.
Alwaysuse extreme caution when cutting and trimming during tting.
Always remove jewelry and wear eye protection.
Never lean over battery while making connections.
Neverrouteelectricalcables:
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.
Alwaysuse 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
INSTALLATIONINSTRUCTIONS
WINCHMOUNTINGKIT
PartNumber:83405
Application:2009-2010HondaBigRed
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 identies 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 recom-
mendations. 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.
PAGE2 83406A0
NOTICE
Equipment Damage
Always refer to the Installation and Specication Guide, supplied in the winch kit, for all wiring schematics and specic details
on how to wire this WARN product to your vehicle.
Read installation and operating instructions thoroughly.
I.BEFOREYOUBEGIN
Before you begin disconnect the positive battery lead from the battery.
CAUTION
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor or moderate injury.
Always take time to fully read and understand the installation and Operations Guide included with this product.
Never operate this product if you are under 16 years of age.
Never operate this product when under the inuence of drugs, alcohol or medications.
Read installation and operating instructions thoroughly.
III.TORQUESPECIFICATIONS
1/4, 6MM 8 lb. ft. (10.8 N-m)
5/16, 8MM 17 lb. ft. (12.5 N-m)
3/8, 10MM 30 lb. ft. (40.7 N-m)
7/16, 11MM 50 lb. ft. (67.8 N-m)
1/2, 12MM 75 lb. ft. (101.7 N-m)
IV.TOOLSREQUIRED
- 10mm, 13mm, 14mm, 15mm, 17mm Socket
- Standard Screwdriver
- 14mm, 17mm wrench
- Socket Driver
- Socket u-joint, extension
II. TABLEOFCONTENTS
Torque Specications page 2
Tools Required page 2
Parts List page 3
Installation page 4-9
Maintenance/Care page 10
PAGE3 83406A0
V.PARTSLIST
No. Part Number Qty Description
A1 82139 1 Mounting Plate
A2 80516 1 Left Fairlead Mounting Bracket
A3 80517 1 Right Fairlead Mounting Bracket
B1 83069 2 M10x1.25x45mm Hex Head Capscrew
B2 11524 4 3/8 Flat Washer
B3 73783 4 M10x1.25 Hex Flange Head Nut
C1 74514 2 M10x1.5x20mm Hex Head Capscrew
D1 74317 2 M10x1.25x25mm Hex Head Capscrew
D2 7482 2 10mm Lock Washer
E1 22508 4 M8x1.25x25mm Capscrew
E2 1402 4 5/16 Lock Washer
B2
B1
A3
A2 B2
B3
B3
A1
C1
B1
B2
E2
E1
E2
D1
D2
E1
PAGE4 83406A0
VI.INSTALLATION
1. Remove capscrews on side of bumper, as
shown in Figure 1, using a 14mm socket.
The top mounting hardware will be used for
reinstallation of the bumper.
2. Remove capscrews at bottom of bumper skid
plate using a 10mm socket, as shown in Fig-
ure 2. This hardware will be used for rein-
stallation of bumper. Remove bumper from
vehicle.
3. Using a screwdriver, remove and save the
two lower pin clips that retain the grill. Refer
to Figure 3.
Figure2
Figure3
Figure1
Remove Capscrews
Remove Capscrews
Remove Lower Pin Clips
PAGE5 83406A0
4. Remove and save the two middle pin clips
that retain grill, as shown in Figure 4.
5. Remove and save the two top pin clips that
retain grill, as shown in Figure 5.
6. Close hood and remove grill from vehicle, as
shown in Figure 6.
INSTALLATION CONT.
Figure4
Figure5
Figure6
Remove Middle Pin Clips
Remove Top Pin Clips
PAGE6 83406A0
Figure7
INSTALLATION CONT.
7. Remove capscrews from frame of vehicle
located near front differential, using a 14mm
socket, as shown in Figure 7. These cap-
screws will not be required when installing
winch mounting plate.
8. Assemble fairlead brackets and winch to
mounting plate in proper orientation, as
shown in Figures 8 and 8a. Bracket orienta-
tion dependent on which winch will be in-
stalled. Use M8x1.25x25mm capscrews and
lock washers to secure but do not tighten at
this time. Temporarily install fairlead using
M10x1.25x25mm capscrews to align fairlead
brackets and then torque 8mm hardware to
17lb. ft. (12.5 N-m). Remove fairlead from
assembly and cut plastic cable ties and elastic
band off winch.
Figure8
Figure8a
Fairlead bracket orientation for RT/XT 40 installation
Fairlead bracket orientation for RT/XT 25/30 installation
Remove capscrews
PAGE7 83406A0
Figure9
INSTALLATION CONT.
9. Install mounting plate assembly on the ve-
hicle, as shown in Figure 9. Slide assembly
between frame tube and radiator shroud in
a horizontal position with winch up. Once
the assembly is past the radiator shroud,
rotate the winch down and rearward and rest
against the vehicle frame. Shift the winch
clutch handle to freespool by rotating clock-
wise, then pull out 12 inches of winch cable
between fairlead brackets. Reinstall vehicle
grille with pin clips removed previously.
10. Pull the winch cable through bumper and
position bumper for installation on vehicle,
as shown in Figure 10. Fairlead brackets
will extend through front of bumper when
bumper is properly positioned.
11. Reinstall the top bumper mount capscrews
which were removed in Step 1, as shown in
Figure 11. Do not tighten at this time.
Figure10
Figure11
PAGE8 83406A0
Figure12
INSTALLATION CONT.
12. Install the M10x1.25x45mm capscrews into
lower bumper mount, as shown in Figure
12. Verify they pass through the slots in the
winch mounting plate on inside of vehicle
frame tubes. Torque both upper and lower
bumper mount hardware to specications
found on page 2. Reinstall lower factory
bumper hardware on front of skidplate.
13. Install the M10x1.5x20mm capscrews and
at washers into vehicle frame through lower
slots of winch mounting plate, as shown in
Figure 13. Do not tighten at this time.
14. Install the M10x1.25 ange head nuts on
inside of winch mounting plate, as shown in
Figure 14.
Note: For easier installation use a u-joint
and extension placed in-between fairlead
mount brackets from front of bumper for
access to install nuts.
Torque these nuts and capscrews in step 13
to specications found on page 2.
Figure13
Figure14
M10x1.5x20mm cap-
screws
PAGE9 83406A0
THEWINCHMOUNTINGPLATEINSTALLATIONISNOWCOMPLETE.
• Wirewinchaccordingtoinstructionsfoundinwinchkit.
PROCEEDTOSECTIONTITLED“MAINTENANCE/CARE”.
READTHEVEHICLE’SOPERATORMANUAL,
WINCHOPERATORMANUAL,ANDALLWARN-
INGLABELSPRIORTOOPERATIONOFUTV
ANDWINCH.
WARNING
Figure16
INSTALLATION CONT.
15. Feed winch cable through fairlead (provided
in winch kit) and mount to fairlead brackets,
using M10x1.25x25mm capscrews, lock
washers and ange nuts. Torque to proper
specications. Install hook and strap to
loop on end of winch cable (also provided in
winch kit).
16. Figure 16 shows a completed installation.
PAGE10 83406A0
VII.MAINTENANCE/CARE
1.Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware
that appears rusted or deformed.
2. Inspect all nuts and bolts on the winch, winch mount, and related hardware prior to each use. Tighten all
nuts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced.
3. Check all cables prior to use. Replace cables that look worn or frayed.
4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.
WARNING
PERFORMREGULARINSPECTIONSONTHEWINCH,WINCHMOUNT,ANDRELATEDHARD-
WARE.NEVEROPERATETHEWINCHWITHDAMAGEDORMISSINGPARTS.FAILURETOFOL-
LOWTHISWARNINGMAYCAUSEVEHICLEDAMAGEANDOPERATORINJURYORDEATH.
FAILURETOSECURELYTIGHTENALLBOLTS
ONTHEWINCHPLATE,WINCH,ANDFAIRLEAD
CANRESULTINPRODUCTFAILUREWHICH
MAYRESULTINVEHICLEDAMAGEANDOP-
ERATORINJURYORDEATH.DOUBLECHECK
THATALLBOLTSARESECURELYTIGHTENED
PRIORTOUSE.
WARNING
Indice
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