INSTALLATION INSTRUCTIONS

Transcription

1 Accessory Application Publication No. INSTALLATION INSTRUCTIONS WINCH MOUNT P/N 08L73-HL4-F01 After 16 SXS1000M3/M3P/M3LE SXS1000M5P/M5D/M5LE MII Issue Date February 2017 PARTS LIST No. Description Qty (1) (28) (27) (26) (1) Installation Instructions URL 1 (2) Winch power cables* 1 (3) Winch battery cable 1 (4) Remote control sub harness 1 (9) (4) (21) (22) (5) Winch sub harness 1 (6) Wire tie 19 (7) Clip band 1 (7) (20) (6) (12) (14) (15) (13) (8) Contactor cover 1 (9) Harness clip stay 1 (10) Contactor stay 1 (11) Contactor plate nut 1 (12) 5 mm nut 2 (13) 5 mm bolt 2 (14) Washer 2 (25) (8) (15) Lock washer (small) 2 (23) (10) (19) (16) 6 mm flange bolt 2 (17) 5 mm shoulder bolt 2 (18) Rubber washer 2 (24) (16) (19) 5 mm flange nut 2 (20) Winch bracket 1 (3) (11) (18) (17) (21) 10 mm flange nut 2 (22) 10 mm flange bolt 2 (23) Lock washer (large) 4 (24) 8 mm bolt 4 (2) (25) 10 mm bolt washer 2 (26) Right roller bracket 1 (27) Left roller bracket 1 (28) 8 mm flange bolt 2 *Some winch power cables will have five clip bands; updated cables will have only three clip bands. (B, C) (5) If your winch power cables have five clip bands, bands B and C (indicated in the illustration), will not be used for installation American Honda Motor Co., Inc. - All Rights Reserved. 1 of 18 08L72-HL4-F01

2 WINCH KIT Sold separately (7) (12) (10) (11) CUSTOMER INFORMATION: The information in these installation instructions is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your SxS. These procedures should not be attempted by Do-it-yourselfers. (1) (8) Not used. BEFORE YOU BEGIN This kit describes the installation of a WARN SxS winch. Please read WARN s Winching Technique guide provided with the winch prior to use of this product. TOOLS AND SUPPLIES REQUIRED Socket (8, 10, 12 and 14 mm) Ratchet (9) (2) Box-end wrench (8, 10 and 14 mm) Side cutters Electric drill (3) Drill bit (5 and 7 mm) (5) Holesaw (18 mm) (4) Marker Ruler (15) Electrical tape (14) (13) Scissors Wire or Wire tie (Length: 290 mm or more/width: 5 mm) (6) Torque wrench No. Description Qty (1) Winch 1 (2) Roller fairlead 1 (3) Hook 1 (4) Clevis pin 1 (5) Cotter pin 1 (6) Strap 1 (7) Remote control switch 1 (8) Contactor 1 (9) 6 mm flange nut 2 (10) 6 mm nut 4 TORQUE CHART Tighten all screws, bolts, and nuts to their specified torque values. Refer to the Service Manual for the torque values of the removed parts. Item N m kgf m Ibf ft 5 mm bolt and nut mm flange nut mm nut mm flange bolt and nut mm bolt mm flange bolt mm flange nut mm bolt washer (11) Lock washer 4 (12) Terminal boot 6 (13) Winching ATV NGW Guide 1 (14) Winch PV4500 Spec Sheet 1 (15) Limited Lifetime Warranty 1 2 of 18

3 MAXIMUM WINCH CAPACITY 1. Remove the vehicle s parts as shown. Winch Capacity 4,500 lb (2,041 kg) SAFETY When installing your SxS winch system, read and follow all mounting and safety instructions. Always use caution when working with electricity and verify that there are no exposed electrical connections before energizing your winch circuit. For specifications and performance data, refer to the specification sheet supplied with your winch. INSTALLATION CAUTION To prevent burns, allow the engine, exhaust system, radiator, etc., to cool before installing the accessory. NOTE: Disconnect the battery negative (-) cable before installing this accessory. The memory of the clock will be erased when you disconnect the battery. Reset the clock after reconnecting the battery. Cut the wire ties at 5 mm from the lock part after attaching them to the wire harnesses. Do not allow the cut part of the wire tie to interfere with another harness or brake hose. Reinstall the removed parts on the vehicle and make sure that the wires and harnesses are not pinched. Always perform the heavy installation work with two people. For installation of this accessory on a SxS equipped with a horn, refer to the installation instructions included with the horn mount. BOLT (Save) BOLT 2. Remove the front bumper as shown. FRONT BUMPER Remove the bolts as shown. BOLT Repeat on the right side. 3 of 18

4 3. Remove the front hood as shown. 6. Tighten the loosely installed parts securely. 7. Drill an 18 mm hole into the instrument panel as shown. Drill hole at the center of the marked line. Remove any burrs from the edge of the hole. FRONT HOOD 4. Loosely install the right and left roller bracket to the front bumper as shown. LEFT ROLLER BRACKET RIGHT ROLLER BRACKET INSTRUMENT PANEL (BACK SIDE) MARKED LINE ELECTRIC DRILL (18 mm HOLE SAW) 8. Position the remote control sub harness as shown and mark this position. REMOTE CONTROL SUB HARNESS 8 mm FLANGE BOLT FRONT BUMPER (Reuse) 5. Install the roller fairlead as shown. FRONT BUMPER 10 mm FLANGE NUT INSTRUMENT PANEL (BACK SIDE) MARKER 10 mm FLANGE BOLT ROLLER FAIRLEAD Make sure that the bigger roller is positioned on the bottom. 4 of 18

5 9. Remove the remote control sub harness and drill at the marked point on the instrument panel using an electric drill. Remove any burrs from the edge of the hole. 11. Install the remote control sub harness as shown. INSTRUMENT PANEL (BACK SIDE) 5 mm BOLT WASHER INSTRUMENT PANEL (BACK SIDE) MARK ELECTRIC DRILL (5 mm BIT) REMOTE CONTROL SUB HARNESS LOCK WASHER (small) 5 mm NUT 10. Open the glove box and pass the remote control sub harness through the hole in the instrument panel. 12. Drill holes into the front fender as shown. Drill holes at the center of the marked lines. Remove any burrs from the edge of the hole. Be careful not to damage the harness. FRONT FENDER OPENED HOLE REMOTE CONTROL SUB HARNESS INSTRUMENT PANEL MARKED LINE ELECTRIC DRILL (7 mm BIT) 5 of 18

6 13. Install the contactor to the contactor stay as shown. 5 mm FLANGE NUT 15. Route and connect the winch sub harness to the accessory socket as shown. WINCH SUB HARNESS STAY 5 mm SHOULDER BOLT RUBBER WASHER ACCESSORY SOCKET 2-PIN WATERPROOF CONNECTOR (Black) 14. Install the assembled contactor to the front fender as shown. 6 mm FLANGE BOLT 16. Connect the vehicle s harness to the winch sub harness as shown. WINCH SUB HARNESS ASSEMBLED FRONT FENDER 2-PIN WATERPROOF CONNECTOR (Black) OPENED HOLE PLATE NUT HORN SUB HARNESS VEHICLE S HARNESS When also installing the Horn mount: 2-PIN WATERPROOF CONNECTOR (Black) WINCH SUB HARNESS 2-PIN WATERPROOF CONNECTOR (Black) VEHICLE S HARNESS 6 of 18

7 17. Secure the winch sub harness with the wire tie as shown. WINCH SUB HARNESS 19. Secure the harnesses with the wire ties as shown. REMOTE CONTROL SUB HARNESS 3-PIN WATERPROOF CONNECTOR (White) WINCH SUB HARNESS WIRE TIE Secure the winch sub harness to the vehicle s harness. 18. Connect the winch sub harness and remote control sub harness as shown. WIRE TIE Secure remote control sub harness to the vehicle s harness. 20. Remove the bolt as shown. <Right side> WIRE TIE Secure winch sub harness to the vehicle s harness. REMOTE CONTROL SUB HARNESS 3-PIN WATERPROOF CONNECTOR (White) WINCH SUB HARNESS BOLT REMOTE CONTROL SUB HARNESS RUBBER 7 of 18

8 21. Install the harness clip stay as shown. 23. Secure the winch power cables with the wire tie as shown. WIRE TIE Secure the winch power cables to the frame. BOLT (Reuse) HARNESS CLIP STAY When also installing the Horn mount: 24. Remove the coolant reserve tank from the stay by pulling it up while leaving the hoses connected. Set the reserve tank to the side. HARNESS CLIP STAY RESERVE TANK 6 mm FLANGE BOLT Included in the Horn mount. ASSEMBLED HORN 22. Install the winch power cables as shown. CLIP BAND HARNESS CLIP STAY 8 of 18

9 25. Route the winch power cables along the frame under the front panel. Secure the winch power cables with the wire ties as shown. Front Fender not shown for clarity. 28. Install the winch power cables as shown. WIRE TIE 26. Reinstall the coolant reserve tank in the reverse order of removal. 27. Route the winch power cables and secure them with the wire tie as shown. CLIP BAND WIRE TIE Secure the winch power cables to the frame. 9 of 18

10 29. Install the terminal boots as shown. 31. Install the winch to the winch bracket as shown. WINCH TERMINAL BOOT Pass the winch power cables through. WINCH BRACKET LOCK WASHER (large) 8 mm BOLT 30. Remove the wire tie as shown. Pull out the wire over the bracket as shown. WIRE TIE Remove. WINCH BRACKET WIRE WINCH 10 of 18

11 32. Loosely install the assembled winch as shown. <Front side> 34. Remove the blue tape from the factory installed winch ground cable. Remove the indicated clip band from the front fender. Remove Blue Tape Remove Clip Band BOLT (Reuse) 35. Route the winch power cables through the hole in the front fender as shown. FRONT FENDER ASSEMBLED WINCH 33. Install the winch power cables as shown. WINCH POWER CABLE TERMINAL TERMINAL BOOT Cover the terminal. TAPE (Yellow) TAPE (Blue) 6 mm FLANGE NUT Included in the Winch kit. 6 mm FLANGE NUT Included in the Winch kit. ASSEMBLED WINCH 11 of 18

12 36. Route the winch sub harness along the main harness as shown. WINCH SUB HARNESS 38. Install the terminal boots as shown. TERMINAL BOOT Pass the winch power cables through. 37. Connect the sub harness to the contactor as shown. SUB HARNESS 39. Install the winch power cables to the corresponding color terminal on the contactor as shown. Install in the direction as shown. WINCH POWER CABLE WINCH POWER CABLE 6 mm NUT LOCK WASHER Included in the Winch kit. TAPE (Yellow) 12 of 18 TAPE (Blue)

13 40. Remove the vehicle s harness from the starter relay switch as shown. 42. Remove the cover as shown. NUT COVER (Discard) VEHICLE S HARNESS STARTER RELAY VEHICLE S HARNESS 43. Connect the winch battery cable as shown. NUT (Reuse) Tighten together with the winch battery cable and vehicle s harness. COVER Cover the terminals after tightening the nut. WINCH BATTERY CABLE 41. Cut the cover as shown. COVER TAPE (Discard) STARTER RELAY VEHICLE S HARNESS VEHICLE S HARNESS COVER SCISSORS Cut. 13 of 18

14 44. Install the terminal boot as shown. 46. Install the terminal boot as shown. WINCH BATTERY CABLE WINCH GROUND CABLE TERMINAL BOOT Pass the winch battery cable through. TERMINAL BOOT Pass the winch ground cable through. WINCH GROUND CABLE WINCH BATTERY CABLE 45. Install the winch battery cable as shown. Install in the direction as shown. 47. Install the winch ground cable as shown. Install in the direction as shown. WINCH BATTERY CABLE WINCH GROUND CABLE 6 mm NUT LOCK WASHER Included in the Winch kit. LOCK WASHER Included in the Winch kit. 6 mm NUT WINCH GROUND CABLE WINCH BATTERY CABLE 14 of 18

15 48. Cover each cable terminal with the terminal boot as shown. 50. Install the clip band as shown, and secure it to the front fender. WINCH GROUND CABLE CLIP BAND Bundle the winch ground cable and winch sub harness. TERMINAL BOOT Cover the terminals. TERMINAL BOOT Cover the terminals. 49. Install the contactor cover as shown. COVER WINCH SUB HARNESS FRONT FENDER CLIP BAND OPEN HOLE 51. Secure the winch ground cable and sub harness with the wire tie as shown. WINCH GROUND CABLE WINCH SUB HARNESS WIRE TIE Secure the winch ground cable and winch sub harness to the vehicle s harness. 15 of 18

16 52. Secure the winch sub harness with the wire ties as shown. 54. Remove the loosely installed bolts. Repeat on the right side. WINCH SUB HARNESS WIRE TIE Secure the winch sub harness to the frame. BOLT WINCH BRACKET 53. Temporarily install mechanic s wire or a wire tie as shown to secure the winch bracket to the A-arm. <Left side> 55. Install the front bumper and winch bracket as shown. Repeat on the right side. After installing winch bracket, remove the wire or wire tie. FRONT BUMPER MECHANIC S WIRE or WIRE TIE Secure the winch bracket to the A-arm. WINCH BRACKET BOLT (Reuse) BOLT (Reuse) WINCH BRACKET 10 mm BOLT WASHER Do not install when the vehicle is equipped with the plow. WIRE ROLLER FAIRLEAD 16 of 18

17 56. Install the hook and strap as shown. <Front side> 57. Connect the remote control switch as shown. <Right side> COTTER PIN After connecting, put the remote control switch in the glove box as shown. CLEVIS PIN REMOTE CONTROL SWITCH GLOVE BOX COTTER PIN CLEVIS PIN HOOK STRAP REMOTE CONTROL SWITCH INSTRUMENT PANEL 58. Confirm that wire harnesses are not caught or too tight. 59. Connect the battery negative (-) cable and check the function of all lights. 17 of 18

18 CHECK THE SYSTEM: 60. Before using the winch, verify the following: The wiring to all components is correct. All loose wires are secured tightly using wire-ties. There are no exposed wires or terminals. Cover any exposed wires or terminals with terminal boots, heat shrink tubing, or electrician s tape. Turn the vehicle ignition switch to the ON position. Check the winch for proper operation. The wire rope should spool in and out in the direction indicated on the switch. 18 of 18