INSTALLATION INSTRUCTIONS ATV Plow Mounting Kit Part Number: 65070 Application: 2003+ Honda Rincon
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 judgment. CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT. This guide identifies 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
WARNING
SEVERE INJURY OR DEATH MAY RESULT IF YOU IGNORE ANY OF THE FOLLOWING. • Read the Plow Operator’s Manual, the Winch Operator’s Manual, and all warning labels before operating. • Operate ATV at a walking speed with the blade installed. Do Not exceed 5mph (8 km/h) even with the blade up. • Plow Cautiously, impact with a hidden or stationary object may cause the ATV to stop suddenly or go out of control. • Do Not operate the ATV on slopes greater than 10° with the plow installed. • Do Not stand or ride on the plow. • Stay clear of moving parts and joints. Keep others away when operating or adjusting plow. • Inspect the plow mechanism, fasteners, cable, and adjustments before operating. Replace all worn or damaged parts before operating. • Lower the plow to the down position before leaving the ATV unattended.
WARN® INDUSTRIES
PAGE 1
65071 Rev A1
C1
C2
C1
C2
C3
C3
C4
C4
A1
C3
C3
B1
C4
C3
C4
C3
C3
C3
D3
D2
C4
C4
C4
C4
D1
A2
B2
B3
I. Parts List Ref
II. Tools Required • Ratchet • Sockets:
Part # Description
Qty
A1 65075 Plow Mount A2 62845 J-bolt Bracket B1 35391 1/4” dia J-bolt B2 1320 1/4” dia flat washer
1 1 2 2
7/16”, 1/2”, 9/16”
• Wrenches:
7/16”, 9/16”
B3 6725 1/4” dia nylock nut 2 C1 60664 5/16” dia x 1-1/8” wide U-bolt 2 C2 60869 5/16” dia x 1-3/8” wide U-bolt 2 C3 1324 5/16” dia flat washer 8 C4 2002 5/16” dia nylock nut 8 D1 1827 3/8” dia x 1” long bolt 1 D2 11524 3/8” flat washer 1 D3 6779 3/8” nylock nut 1
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65071 Rev A1
III. Installation 1. Slide two 5/16” dia x 1-1/8” wide U-bolts (C1) over the rear frame cross tubes as shown in figure 1. 2. Place the plow mount (A1) under the vehicle, and slide the legs of the U-bolts through the four rear holes in the plow mount. Terminate the U-bolt legs with 5/16” dia flat washers (C3) and 5/16” dia nylock nuts (C4) as shown in figure 2. NOTE: Do not tighten the bolt and nut completely. You will do this later in the installation. 3. Slide two 5/16” dia x 1-3/8” wide U-bolts (C2) over the large side frame tubes under the vehicle and through the plow mount (A1) as shown in figure 3.
C1
C1
Front of Vehicle
Figure 1 Install Rear U-Bolts
C1, C3, & C4
A1
Front of Vehicle
Figure 2 Install Plow Mount
C2
C2
Rear of Vehicle
Figure 3 Install Front U-Bolts
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65071 Rev A1
4. Terminate the ends of the two 5/16” dia x 1-3/8” wide U-bolts (C2) with 5/16” dia flat washers (C3) and 5/16” dia nylock nuts (C4) as shown in figure 4. 5. Tighten all the 5/16” dia nylock nuts (C4) on the plow mount (A1) to a recommended torque of 12 ft-lb (16 N-m). The completed plow mount should look like figure 5. WARNING Tighten all nuts and bolts securely. Failure to check all nuts and bolts prior to use can result in product failure which can lead to vehicle damage and operator injury or death. 6. If not already done so, assemble the plow per the instructions that came with the plow blade kit. Attach the plow to the plow mount (A1) using the clip pins that came with the plow blade. If using an electric actuator or manual lift to raise your plow, stop here and proceed to section IV, Maintenance/Care. Winch users continue with step 7. 7. Attach the J-bolt bracket (A2) to the center hole in the plow crossmember using a 3/8” dia x 1” long bolt (D1) as shown in figure 6. The bracket should be mounted on the blade side of the crossmember with the side flanges parallel to the ground. Terminate the bolt with a 3/8” dia flat washer (D2) and 3/8” dia nylock nut (D3). Tighten the bolt and nut to a recommended torque of 20 ft-lb (28 N-m).
Rear of Vehicle
C2, C3, & C4
Figure 4 Install Remaining Fasteners
Figure 5 Completed Plow Mount
D1, D2, & D3
A2
Figure 6 Installed J-bolt Bracket
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65071 Rev A1
8. Run the winch cable over the roller fairlead and down to the J-bolt bracket (A2). Using a 1/4” dia J-bolt (B1), hook the loop on the end of the winch cable and slide the threaded end of the J-bolt through the round holes in the J-bolt bracket. The hook end of the J-bolt should slide into the slotted hole in the J-bolt bracket. Terminate the end of the J-bolt with a 1/4” dia flat washer (B2) and 1/4” dia nylock nut (B3). Tighten the nut until the winch cable is snug inside the J-bolt as shown in figure 7. NOTE: Do not remove the winch hook installed on the end of the winch cable, simply slide it out of the way. CAUTION The purpose of the J-bolt is to break the connection between the plow and ATV when the plow is subjected to high forces that could damage the plow or vehicle. The plow will drop instantly if the J-bolt breaks, so be sure there are no bystanders when operating the plow. Instances when the J-bolt might break are: • If the plow is raised too high and stalls. • If the operator is trying to lift too much material with the plow blade. Plow mount installation is now complete and should look like figure 8. Proceed to the next section entitle Maintenance/Care. plow. After pushing material with the plow, backup the ATV prior to raising it. If the J-bolt breaks, replace it with the spare hardware found in this kit. Read the Plow Operators Guide for more information. In general, do not raise the top of the plow blade above the headlights of the vehicle. If the plow stalls, stop the winch immediately and lower the
Cable End
B1, B2, & B3
Figure 7 J-bolt and Winch Cable
Figure 8 Completed Winch and Plow Assembly
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65071 Rev A1
IV. Maintenance/Care • Inspect all metal parts on the plow, plow mount, and related hardware. Replace all parts that appears rusted or deformed prior to use. • Inspect all nuts and bolts on the plow, plow mount, and related hardware prior to each use. Tighten all nuts and bolts that appear to be loose. Stripped, fractured, or bent bolts or nuts need to be replaced immediately. • 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 part from moving freely. WARNING Failure to perform regular inspections and maintenance on the plow, plow mount, and related hardware may result in vehicle damage and operator injury or death.
V. Troubleshooting Problem 1. Difficulty getting the plow clip pins through the plow flanges and plow mount (A1).
Solution
1. Be sure to install the plow on level ground. Position the plow into place. Align one of the plow flanges with the mounting hole in the plow mount (A1). Slide a screwdriver (or similar) through the plow flange and plow mount. Align the plow flange on the other side with the plow mount. Slide one of the clip pins through the plow flange and plow mount. Go back to the first plow flange. Remove the screwdriver and replace it with the clip pin.
WARN® INDUSTRIES
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65071 Rev A1
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