Warn 84704 Manuale utente
WARN INDUSTRIES PAGE 1 84855A2
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, 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.
Always use extreme caution when cutting and trimming during tting.
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: 84704
Application: Honda Rancher TRX420
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
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.
WARN INDUSTRIES PAGE 2 84855A2
Table of Contents
I. Parts List..........................................................................3
II. Tools Required.................................................................3
III. Rancher TRX420 Installation......................................4-11
IV. Winch Wiring..................................................................12
V. TRX 420 Specic Wiring Instructions .......................13-16
VI. Maintenance/Care .........................................................17
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.
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.
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.
WARN INDUSTRIES PAGE 3 84855A2
II. Tools Required
•Ratchet
•Sockets: 10mm, 12mm, 13mm, 7/16”
•Wrenches: 10mm, 13mm, (2) 14mm, 3/8”, 7/16”
•Screwdrivers: Slotted, Phillips
•Allen Wrenches: 1/8”, 5mm
•Sidecutters or Saw
•Voltmeter or Test Light
•Electric Tape
I. Parts List
Ref Description Qty
A1 Upper Mounting Bracket 1
A2 Lower Mounting Bracket 1
A3 Side Mounting Bracket 1
B1 8mm-1.25 x 30mm Bolt 4
B2 8mm Flat Washer 8
B3 9.5mm (3/8”) Spacer 2
B4 6mm - 1.00 x 12mm Bolt 2
B5 6.3mm (1/4”) Spacer 1
B6 8mm-1.25 Lock Nut 1
1/4-20 x 1” x 1 3/4” U-bolt 2
1/4-20 Lock Nut 4
1/4 Flat Washer 4
Winch Mounting Slots
WARN INDUSTRIES PAGE 4 84855A2
III. Rancher TRX420 Installation
1. Begin by removing the two plastic rivets on each
side of the front plastic fascia, gure 1. 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 reinstall the front plastic fascia.
2. Remove the two side 6mm bolts securing the front
fascia, gure 2. Save the fasteners as they will be
used later to reinstall the front fascia. Remove the
front plastic fascia.
3. Remove the four 6mm bolts that secure the front
skid plate, gure 3. Save the fasteners as they will
be reinstalled later.
Figure 2 Remove Front Fascia
Figure 1 Remove the Two Plastic Rivets
Figure 3 Front Skid Plate Bolts
Remove
(both sides)
Remove
(both sides)
Remove
WARN INDUSTRIES PAGE 5 84855A2
4. Remove the two 6mm bolts that attach the front
bumper to the plastic headlight assembly, gure 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, gure 5.
Save the fasteners as they will be used to reinstall
the front bumper.
6. Remove the four remaining bumper bolts that
attach the bumper to the vehicle frame, gure 6.
Remove the bumper from the vehicle at this time.
Figure 5 Remove Top Bumper Bolts
Figure 4 Front Bumper Bolts
Figure 6 Remove Bumper Bolts
Remove (both sides)
Remove (both sides)
Remove (both sides)
WARN INDUSTRIES PAGE 6 84855A2
7. Depress the side tabs and remove the plastic
radiator panel from the vehicle, gure 7. This
panel will be reinstalled later.
8. Attach the winch to the lower mounting bracket
(A2), gure 8. Use the two 8mm-1.25 x 20mm
bolts and lock washers supplied with the winch,
and place a 8mm at washer (B2) between each
lock washer and the lower mounting bracket. Do
not tighten the bolts at this time.
Note: The end loop of the wire rope must be acces-
sible from the top of the drum. If necessary,
put the winch in freespool and rotate the drum
so that the wire rope end is no longer under-
neath the bracket.
9. Place the winch and lower mounting bracket
assembly into position in the front bumper,
gure 9.
Figure 9 Place Winch in Bumper
Figure 7 Remove Plastic Radiator Panel
Figure 8 Attach Winch onto Lower Mounting Bracket
Remove
Side Tabs
A2
Top of Drum
8mm Winch Bolts,
Lock Washers, and Flat Washers
WARN INDUSTRIES PAGE 7 84855A2
10. Place front bumper and loosely positioned winch
assembly back onto the vehicle frame, gure
10. Reinstall the two top bumper bolts that were
removed in step 5. Do not tighten at this time.
11. Place the upper mounting bracket (A1) onto
the vehicle frame, gure 11. Fasten the upper
mounting bracket to the winch with two 8mm-1.25
x 20mm bolts and lock washers supplied with
the winch. Place a provided 8mm at washer
(B2) between each lock washer and the upper
mounting bracket. Do not tighten at this time.
12. Route the wire rope between the upper and lower
mounting brackets (A1) & (A2), so that the end
loop is visible from the front, gure 11.
13. Install two of the supplied 8mm-1.25 x 30mm bolts
(B1) and at 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, gure 12. Do not
tighten at this time.
Figure 12 Bolt and Spacer Location
Figure 11 Upper Mounting Bracket Installation
Figure 10 Place Bumper Back onto Vehicle
Reinstall
End Loop
A1
A1
B3
B2
B1
8mm Winch Bolts,
Lock Washers, and
Flat Washers
WARN INDUSTRIES PAGE 8 84855A2
14. Install the supplied 8mm-1.25 x 30mm bolt (B1)
and at washer (B2) into the lower bumper
mounting location. Make sure that the bolt passes
through the hole on the lower mounting bracket
(A2), gure 13. Place the supplied 8mm lock nut
(B6) on the end of the 8mm bolt (B1). Do not
tighten at this time.
15. Place the side mounting bracket (A3) onto the
bottom mounting bracket (A2) and install the two
supplied 6mm-1.00 x 12mm bolts (B4), gure 14.
Place the 6.3mm spacer (B5) between the side
mounting bracket and the bumper. Fasten the
supplied 8mm-1.25 x 30mm bolt (B1) through the
at washer (B2), side mounting bracket, spacer
(B5), bumper, and into the frame, gure 14 and
gure 17. Do not tighten at this time.
16. Place the motor terminal boots on the supplied
yellow and blue electrical cables. Connect the
yellow and blue cables to the motor terminals on
the winch, gure 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.
B2
B6
B1
A2
Bumper
Figure 13 Lower Bumper Mounting Location
Figure 14 Completed Winch Installation
A3
B1
B2
B4
A2
Figure 15 Connect Yellow and Blue Electrical Cables
Yellow Cable
Blue Cable
WARNING
The 6.3mm (1/4”) spacer must be used to install
the side mounting bracket to the vehicle frame.
Failure to do so can result in product failure
which can lead to vehicle damage and
operator injury or death.
WARN INDUSTRIES PAGE 9 84855A2
17. Position the winch on the brackets to maximize
the clearance between the motor terminals and
the adjacent bumper or frame members, gure 16
and gure 17.
18. Tighten the four winch bolts to a recommended
torque of 17 N-m (12 ft-lb), gure 18. Remove
the small tie bolt. This bolt should be retained
for winch service. Reinstall the two 6mm bolts
removed in step 4. Tighten the six 8mm bumper
bolts, and the four 6mm bolts to a recommended
torque of:
6mm bolts - 12 N-m (9 ft-lb)
8mm bolts - 37 N-m (27 ft-lb)
Terminal Boot
Figure 16 Upper Motor Terminal Clearance
Figure 17 Lower Motor Terminal Clearance
WARNING
Winch must be positioned such that no
fasteners, frame members, or other objects
may come in contact with the motor terminals
and motor terminal boots. Failure to do so can
result in product failure which can lead to vehicle
damage and operator injury or death.
Winch Bolts
(both sides)
8mm Bolts
(both sides)
6mm Bolts
Figure 18 Winch and Mount Bolts
Tie Bolt
B1
B5
A3
Terminal Boot
WARN INDUSTRIES PAGE 10 84855A2
Trim Skid Plate
Figure 19 Skid Plate Trim Location
6mm Bolt
Roller Fairlead
10mm Bolts
Figure 20 Roller Fairlead Installation
Figure 21 Front Fascia Reinstalled
19. Trim the plastic skid plate for winch clutch dial
clearance, gure 19. Skid plate should not touch
the dial when the 6mm mount bolt is installed.
20. Install the roller fairlead using the two 10mm bolts,
lock washers, and nuts supplied with the winch,
gure 20.
21. Reinstall the plastic radiator panel removed in step
7. Move the front plastic fascia into position over
the roller fairlead, gure 21. Reinstall the two side
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.
Indice
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