INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS PARTS LIST Accessory Application Publications No. TRX420 (All) MII WINCH KIT P/N 08L94-HP5-100 Accessory Weight 35 lbs (16 kg) Honda Dealer: Please give a copy of these instructions to your customer. (21) (14) (18) (1) (20) (19) (2) (16) (17) (6) (24) (23) (5) (4) (7) (22) Issue Date Revised September 2010 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 (9) (8) (3) (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 (13) (12) (10) (11) (15) 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

2 WINCH KIT (16) (18) (17) (7) (1) (5) (4) (3) (2) CUSTOMER INFORMATION: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your ATV. These procedures should not be attempted by Do-It-Yourselfers. (14) (8) (9) (6) BEFORE YOU BEGIN This kit includes a WARN ATV winch. Please read WARN s Winching Technique guide provided with the winch prior to use of this product. (13) (12) (11) (10) (15) 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 TOOLS AND SUPPLIES REQUIRED Socket (10 mm, 12 mm, 13 mm, 17 mm, 7/16 in) Rachet Box-end wrench (10 mm, 13 mm, 14 mm, 17 mm, 3/8 in, 7/16 in) Phillips screwdriver Allen wrenches (1/8 in, 5 mm) Side-cutters or Saw Voltmeter or test light Electrical tape Scissors Torque wrench 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 nut mm bolt mm bolt mm lock nut mm bolt mm lock nut mm nut (14) Winch nut 2 (15) Switch 1 (16) Contactor 1 (17) Contactor nut 8 (18) 6mm Spring washer 8 2 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

3 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 all nuts and bolts that are loose. Missing, stripped, fractured, or bent bolts or nuts need to be replaced immediately. Subtract the weight of this accessory (35 lbs) from the front cargo rack weight limit (66 lbs). Do not load more than 31 lbs. of cargo on the front rack. Check all cables prior to use. Replace cables that are worn or frayed. Check all moving and rotating parts. Remove debris that may inhibit the free movement of any parts. INSTALLATION NOTES: Disconnect the negative cable from the battery before installing this accessory. The memories of the tripmeter and clock will be erased when you disconnect the battery. Reset the clock after reconnecting the battery. Trim the excess ends off the wire ties 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. 1. Allow the engine and exhaust system to cool before installing this accessory. 2. Remove the parts, and disconnect the negative terminal of the battery. Winch Capacity 4000 lbs SEAT NOTICE Failure to perform regular inspections and maintenance on the winch, winch mount, and related hardware may result in vehicle damage. REAR COVER SAFETY When installing your ATV 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. RIGHT AND LEFT TANK SIDE COVER 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

4 3. Remove the side covers as shown. 6. Disconnect the connector as shown. LEFT SIDE COVER CONNECTOR METER Lay back against the fuel tank cover. CLIP RIGHT SIDE COVER 4. Remove the hose as shown. HOSE Pull out. 7. Remove the fuel tank cap as shown. FUEL TANK CAP Remove. 5. Remove the indicated nuts. NUT 4 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

5 8. Remove the six trim clips and tank cover as shown. CLIP 10. Remove the indicated clips from the left radiator grill cover. CLIP CLIP CLIP TANK COVER 11. Remove the indicated connector. 3-PIN CONNECTOR (Black) Remove. 9. Install the fuel tank cap as shown. FUEL TANK CAP 12. Remove the left radiator grille cover as shown. LEFT RADIATOR GRILLE COVER 13. Remove the right radiator grille cover in the same manner American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

6 14. Assemble the switch as shown. 3 mm SCREW STOPPER WASHER (small) SWITCH BRACKET 17. Route the switch harness as shown. WIRE TIE (Reuse) Secure to the vehicle s harness. SWITCH WIRE TIE (Reuse) Secure to the handlebar together with the vehicle s harness. 15. Loosely install the holder as shown. HOLDER 5 mm NUT HOLDER CLAMP Route the harness through the clamp. 5 mm SOCKET (SHORT) 18. Route the switch harness as shown. 16. Install the switch as shown. Tighten the upper bolt first, then tighten the lower bolt. STOPPER WASHER (large) 5 mm NUT 5 mm SOCKET (LONG) SWITCH 6 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

7 19. Route the bullet connector side of the switch harness to the rear as shown. 21. Insert the cap into the 2P White connector and connect the switch harness to the accessory socket as shown. Bundle any excess wire with a wire tie. ACCESSORY SOCKET (Black) BULLET CONNECTORS CAP Insert. 2P WHITE CONNECTOR 22. Pass battery cable through the terminal boot as shown. Repeat on the battery cable (red). 20. Locate the accessory socket on the right radiator grill and remove the cap as shown. Route the 2P white connector end of the switch harness toward the socket. ACCESSORY SOCKET BATTERY CABLE (Black) TERMINAL BOOT 23. Install terminal boots at both ends of each power cable as shown. TERMINAL BOOT CAP Remove. POWER CABLE (Yellow and Blue) 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

8 24. Loosely install the contactor to the frame as shown. 26. Route the battery cables as shown. Top view BLUE BLACK BATTERY CABLE (Red) BATTERY CABLE (Black) CONTACTOR RED FRONT YELLOW 1/4-20 in LOCK NUT CONTACTOR 1/4 in FLAT WASHER U- 25. Connect the battery cables to the corresponding color terminals on the contactor as shown. BATTERY CABLE (Red) 6 mm NUT FUSE BOX 6 mm SPRING WASHER 27. Connect the power cables to the corresponding color terminals on the contactor as shown.. POWER CABLE (Blue) 6 mm NUT 6 mm SPRING WASHER POWER CABLE (Yellow) BATTERY CABLE (Black) 8 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

9 28. Cover each cable connector with the terminal boot as shown. TERMINAL BOOT Cover the connectors. TERMINAL BOOT Cover the connectors. 30. Rotate the contactor towards the rear as shown and secure it. Tighten the 6 mm lock nuts as shown. Adjust so that it becomes horizontal. CONTACTOR Push down the connected contactor harness toward the rear to store it. 29. Connect the contactor harness as shown. CONTACTOR HARNESS 6 mm LOCK NUTS 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

10 31. Route each power cable as shown. 33. Route the power cables as shown. Route along the vehicle s harness. RIB Secure each cable. POWER CABLE (Yellow) Route along the vehicle s harness. POWER CABLE (Blue) Route along the vehicle s harness. POWER CABLE (Blue) 32. Route each power cable as shown. RIB Secure each cable. POWER CABLE (Yellow) 34. Remove the clips, bolts, and front pipe guard as shown. CLIP CLIP FRONT PIPE GUARD WIRE TIE (Reuse) Secure both cables. FLANGE FLANGE 10 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

11 35. Remove the indicated bolts. 37. Route the power cable as shown. POWER CABLE (Blue) POWER CABLE (Yellow) FLANGE FLANGE POWER CABLE (Blue) WASHER FLANGE POWER CABLE (Yellow) 36. Lower the skid plate as shown. SKID PLATE 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

12 38. Route the power cables as shown. POWER CABLE (Blue) 40. Remove the indicated bolts as shown. Repeat on the right side. POWER CABLE (Yellow) 41. Remove the bolts front carrier pipe as shown. POWER CABLE (Blue) POWER CABLE (Yellow) 39. Cut off at the indicated portion of the skidplate as shown. After cutting, remove any burrs. (Save) FRONT CARRIER PIPE (Save) SKID PLATE SIDE CUTTERS Cut out. SKID PLATE 12 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

13 42. Remove the radiator grille under cover as shown. 44. Remove the shipping screw and loosely install the assembled lower mounting bracket onto the winch as shown. 8 x 20 mm SPRING WASHER 8 mm FLAT WASHER LOWER MOUNTING BRACKET ASSEMBLY RADIATOR GRILLE UNDER COVER SHIPPING SCREW 43. Assemble the lower mounting bracket as shown. 6 x 12 mm FLANGE WINCH 45. Place the preassembled winch onto the front carrier pipe at the shown position. WINCH LOWER MOUNTING BRACKET SIDE MOUNTING BRACKET FRONT CARRIER PIPE FRONT CARRIER PIPE WINCH 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

14 46. With the winch set, loosely install the front carrier pipe as shown. Perform this work with two people and support the winch so that it does not drop down. 47. Install the upper mounting bracket as shown. < Upper view > SPRING WASHER 8 x 20 mm 8 mm FLAT WASHER UPPER MOUNTING BRACKET Install the 9.5 mm spacer between frame and upper mounting bracket. Do the same also on the right side. 8 mm FLAT WASHER 8 x 30 mm FRONT CARRIER PIPE < Lower view > FRONT CARRIER PIPE 9.5 mm SPACER 48. Install the roller fairlead as shown. ROLLER FAIRLEAD 10 mm NUT 8 mm FLAT WASHER 8 x 30 mm 8 mm LOCK NUT 6.3 mm SPACER 8 mm FLAT WASHER 8 x 30 mm 10 mm SPRING WASHER 10 mm ROLLER FAIRLEAD 14 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

15 49. Install the hook as shown. COTTER PIN 50. Secure the power cables as shown and connect the blue power cable. After connection, cover the cable terminal with the terminal boot to prevent contact with the frame. FLANGE NUT POWER CABLE (Blue) TERMINAL (Blue) CLEVIS PIN COTTER PIN WINCH WIRE TIE Secure the power cables to the frame. HOOK ORANGE PULL STRAP CLEVIS PIN POWER CABLE (Yellow) 51. Connect the yellow power cable as shown. After connection, cover the cable terminal with the terminal boot to prevent contact with the frame. WINCH TERMINAL (Yellow) POWER CABLE (Yellow) FLANGE NUT 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP of 16

16 52. Connect the red battery cable to the positive (+) battery terminal as shown. After connecting, Cover the connectors. Cut the positive (+) battery terminal cover as shown. BATTERY COVER BATTERY (Reuse) SCISSORS CHECK THE SYSTEM: 54. Before using the winch, verify the following: The wiring to all components is correct. All loose wires are wrapped tight using cable-ties. There are no exposed wires or terminals. Cover any exposed wires or terminals with terminal boots, heat shrink 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 on the switch. POSITIVE (+) TERMINAL BATTERY CABLE (Red) 53. Connect the black battery cable to the negative (-) battery terminal as shown. BATTERY CABLE (Black) 55. Install the vehicle s parts in the reverse order of removal. NEGATIVE (-) TERMINAL BATTERY (Reuse) 16 of 16 08L94-HP American Honda Motor Co., Inc - All Rights Reserved.

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS Honda Dealer: Please give a copy of these instructions to your customer. PARTS LIST (15) (8) (12) (14) (13) (10) (11) (18) (17) (1) Accessory Application Publications No. TRX500FA/FGA