Accessory Application Publication No. INSTALLATION INSTRUCTIONS HORN MOUNT P/N 08Z77-HL4-A00 SXS1000M3/M3P/M5D/M5P Honda Dealer: Please give a copy of these instructions to your customer. MII 15262 Issue Date March 2016 PARTS LIST (1) (5) (6) (8) (3) (9) (7) (4) (2) TOOLS AND SUPPLIES REQUIRED Socket (10 and 12 mm) Ratchet Box-end wrench (12 and 22 mm) Electric drill Hole saw (16 and 20 mm) Side cutters 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 6 mm flange bolt 12 1.2 9 8 mm flange nut 27 2.8 20 No. Description Qty 16 mm hex nut 1.5 0.1 1.1 (1) Installation Instructions URL 1 (2) Horn sub harness 1 (3) Horn stay 1 (4) Horn switch 1 (5) 8 mm flange bolt 1 (6) 8 mm flange nut 1 (7) Wire tie 9 (8) 16 mm hex nut 1 (9) 6 mm flange bolt 2 HORN P/N 08P75-HL5-A00 Sold separately (2) (1) No. Description Qty (1) Installation Instructions URL 1 (2) Horn 1 2015 American Honda Motor Co., Inc. - All Rights Reserved. 1 of 12 87970-HL4-0001
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 each wire tie 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. For installation of this accessory on a SxS equipped with the winch mount, refer to the installation instructions included with the winch mount as well. 2. Remove the vehicle s parts as shown. 3. Remove the front bumper as shown. 1. Loosen the band as shown. <Right side> FRONT BUMPER Remove the bolts as shown. SCREW Loosen. BAND Repeat on the right side. DUCT 2 of 12
4. Remove the clips as shown. <Left side> 6. Remove the left front mud guard as shown. LEFT FRONT MUD GUARD 7. Remove the bolt as shown. 5. Remove the left front door as shown. LEFT FRONT DOOR 8. Repeat on the right side. 9. Remove the front hood as shown. FRONT HOOD 3 of 12
10. Remove the battery stay as shown. BATTERY STAY 12. Remove the filter cover as shown. Cover the duct with a shop towel or similar to prevent debris from entering the duct. FILTER COVER DUCT 11. Remove the battery and battery cushion as shown. Disconnect the negative (-) cable first. BATTERY 13. Remove the relay and fuse box as shown. BATTERY CUSHION RELAY FUSE BOX 14. Remove the fuse holder and starter relay switch as shown. FUSE HOLDER STARTER RELAY SWITCH 4 of 12
15. Remove the connectors as shown. 2-PIN WATERPROOF 17. Remove the front fender as shown. Cover the duct with a shop towel or similar to prevent debris from entering the duct. SCREW 6-PIN WATERPROOF 16. Remove the clips as shown. FRONT FENDER DUCT 18. Disconnect the connectors as shown. BATTERY CABLE 4-PIN WATERPROOF 5-PIN WATERPROOF 3-PIN WATERPROOF CONNECTOR (White) 5 of 12
19. Remove the parts as shown. 22. Remove the steering cover as shown. STEERING COVER SCREW SCREW 23. Remove the parts as shown. 20. Remove the screws as shown. SCREW SCREW 24. Disconnect the connector as shown. <Left side> 21. Remove the select lever knob and change lever knob as shown. METER HARNESS CHANGE LEVER KNOB SELECT LEVER KNOB 8-PIN WATERPROOF 6 of 12
25. Remove the instrument panel as shown. INSTRUMENT PANEL 27. Install the horn switch as shown. INSTRUMENT PANEL (Inner side) 16 mm HEX NUT DRILLED HOLE Secure the horn switch. HORN SWITCH Install the horn switch so the horn icon faces the direction shown. 26. Drill the instrument panel as shown. Drill a 16 mm hole at the center of the marked line. Remove any burrs from the edge of the hole. INSTRUMENT PANEL (Inner side) HORN SWITCH 28. Secure the horn switch harness with the wire ties as shown. WIRE TIE Secure the horn switch harness to the vehicle s harness. MARKED LINE ELECTRIC DRILL (16 mm HOLE SAW) INSTRUMENT PANEL (Inner side) HORN SWITCH HARNESS 7 of 12
29. Remove the cap as shown. <Left side> FRONT FENDER (Inner side) 33. Drill the front fender as shown. Drill a 20 mm hole at the center of the marked line. Remove any burrs from the edge of the hole. LEFT HEADLIGHT COVER FRONT FENDER ELECTRIC DRILL (20 mm HOLE SAW) CAP MARKED LINE 30. Remove the clip and connector as shown. FRONT FENDER 3-PIN WATER PROOF CONNECTOR (Green) 31. Repeat on the right side. 32. Remove the headlight harness as shown. HEADLIGHT HARNESS HEADLIGHT HARNESS 34. Install the headlight harness, caps and connectors in the reverse order of removal. 35. Install the horn on the horn stay as shown. 8 mm FLANGE HORN STAY HORN 8 mm FLANGE NUT FRONT FENDER 8 of 12
36. Remove the bolts as shown. <Right side> 38. Pull the rubber guard and remove the indicated connector. FRONT (Save) RUBBER ACCESSORY SOCKET 2-PIN WATERPROOF 37. Install the assembled horn as shown. 39. Route and connect the horn sub harness as shown. 6 mm FLANGE ASSEMBLED HORN When also installing the Winch Mount: ACCESSORY SOCKET 2-PIN WATERPROOF HARNESS STAY ASSEMBLED HORN 6 mm FLANGE 9 of 12
40. Connect the horn sub harness to the vehicle s harness as shown. 42. Install the front fender and instrument panel in the reverse order of removal and route the horn switch harness and horn sub harness as shown. Remove the shop towel/cover from the duct. HORN SWITCH HARNESS VEHICLE S HARNESS 2-PIN WATERPROOF HORN SUB HARNESS When also installing the Winch mount: 2-PIN WATERPROOF CONNECTOR (Black) SUB HARNESS 2-PIN WATERPROOF CONNECTOR (Black) 43. Connect the horn sub harness as shown. 2-PIN WATERPROOF CONNECTOR (White) HORN SWITCH HARNESS VEHICLE S HARNESS 41. Secure the horn sub harness with the wire tie as shown. WIRE TIE Secure the horn sub harness to the vehicle s harness. 10 of 12
44. Pass the horn sub harness through the front fender as shown. 46. Secure the horn sub harness with the wire tie as shown. DRILLED HOLE WIRE TIE Secure the horn sub harness to the frame. 47. Secure the horn sub harness with the wire ties as shown. WIRE TIE Secure the horn sub harness to the vehicle s harness. 45. Route and connect the horn sub harness as shown. <Right side> ASSEMBLED HORN WIRE TIE Secure the horn sub harness to the vehicle s harness. 11 of 12
48. Secure the horn switch harness with the wire ties as shown. HORN SWITCH HARNESS WIRE TIE Secure the horn switch harness to the frame. 49. Install the removed vehicle parts in the reverse order of removal. Confirm that wire harnesses are not caught or too tight. 50. Connect the battery negative (-) cable and check each light for function. 51. Check the horn operation. 12 of 12