trx420 winch kit installation...

© 2010 American Honda Motor Co., Inc - All Rights Reserved. 08L94-HP5-1001-91 1 of 16

PARTS LIST

Accessory Application Publications No.

Issue Date

Honda Dealer: Please give a copy of these instructions to your customer.

INSTALLATIONINSTRUCTIONS

Accessory WeightWINCH KIT

P/N 08L94-HP5-100

TRX420 (All)

Revised September2010

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

(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

(4)(5)(6)

(7)

(13) (12) (10)(11) (15)

(14)

(17)

(16)

(19)(20)

(18)

(21)

(22)

(24)(23)

MII 13032

35 lbs (16 kg)

(1)

(2)

(9)

(3)

(8)

2 of 16 08L94-HP5-1001-91 © 2010 American Honda Motor Co., Inc - All Rights Reserved.

CUSTOMER INFORMATION:The information in this installation instruction is intendedfor use only by skilled technicians who have the propertools, equipment, and training to correctly and safely addequipment to your ATV. These procedures should not beattempted by “Do-It-Yourselfers”.

BEFORE YOU BEGINThis kit includes a WARN ATV winch. Please read WARN’sWinching Technique guide provided with the winch priorto use of this product.

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

(14) Winch nut 2

(15) Switch 1

(16) Contactor 1

(17) Contactor nut 8

(18) 6mm Spring washer 8

(5)

(17)

(9)

(16)

(8)

(7)

(14)

(6)

(1) (4)

(3)

(2)

(13)

(10)

(11)(12)

(15)

WINCH KIT

TORQUE CHARTTighten all screws, bolts, and nuts to their specified torquevalues. Refer to the Service Manual for the torque valuesof the removed parts.

TOOLS AND SUPPLIES REQUIREDSocket (10 mm, 12 mm, 13 mm, 17 mm, 7/16 in)RachetBox-end wrench (10 mm, 13 mm, 14 mm, 17 mm, 3/8 in,7/16 in)Phillips ® screwdriverAllen wrenches (1/8 in, 5 mm)Side-cutters or SawVoltmeter or test lightElectrical tapeScissorsTorque wrench

Item N·m kgf·m Ibf·ft

5 mm nut 5 0.5 3.6

6 mm bolt 12 1.2 9

6.3 mm bolt 7 0.7 5

6.3 mm lock nut 7 0.7 5

8 mm bolt 37 3.7 27

8 mm lock nut 37 3.7 27

10 mm nut 34 3.5 25

(18)


INSTALLATIONNOTES:

• Disconnect the negative cable from the battery beforeinstalling this accessory.

• The memories of the tripmeter and clock will be erasedwhen you disconnect the battery. Reset the clock afterreconnecting the battery.

• Trim the excess ends off the wire ties after attachingthem to the wire harnesses. Do not allow the cut partof the wire tie to interfere with another harness orbrake hose.

REAR COVER

RIGHT AND LEFTTANK SIDE COVER

SEAT

2. Remove the parts, and disconnect the negativeterminal of the battery.

1. Allow the engine and exhaust system to cool beforeinstalling this accessory.

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 allnuts and bolts that are loose. Missing, stripped,fractured, or bent bolts or nuts need to be replacedimmediately.

• Subtract the weight of this accessory (35 lbs) fromthe front cargo rack weight limit (66 lbs). Do not loadmore than 31 lbs. of cargo on the front rack.

• Check all cables prior to use. Replace cables thatare worn or frayed.

• Check all moving and rotating parts. Remove debristhat may inhibit the free movement of any parts.

Winch Capacity 4000 lbs

NOTICEFailure to perform regular inspections and maintenanceon the winch, winch mount, and related hardware mayresult in vehicle damage.

SAFETYWhen installing your ATV winch system, read and followall mounting and safety instructions. Always use cautionwhen working with electricity and verify that there are noexposed electrical connections before energizing yourwinch circuit. For specifications and performance data,refer to the specification sheet supplied with your winch.


3. Remove the side covers as shown.

LEFT SIDE COVER

RIGHT SIDE COVER

BOLT

BOLT

CLIP

7. Remove the fuel tank cap as shown.

HOSEPull out.

5. Remove the indicated nuts.

NUT

6. Disconnect the connector as shown.

CONNECTOR

METERLay back againstthe fuel tank cover.

4. Remove the hose as shown.

FUEL TANK CAPRemove.


8. Remove the six trim clips and tank cover as shown.

CLIP

TANK COVER

9. Install the fuel tank cap as shown.

FUEL TANK CAP

10. Remove the indicated clips from the left radiator grillcover.

11. Remove the indicated connector.

3-PIN CONNECTOR (Black)Remove.

CLIP

CLIP

CLIP

12. Remove the left radiator grille cover as shown.

LEFT RADIATORGRILLE COVER

13. Remove the right radiator grille cover in the samemanner.


14. Assemble the switch as shown.3 mm SCREW

STOPPERWASHER (small)

SWITCH BRACKET

SWITCH

15. Loosely install the holder as shown.

5 mm NUT

HOLDER

HOLDER

5 mm SOCKET BOLT(SHORT)

5 mm NUT

STOPPERWASHER (large)

5 mm SOCKETBOLT (LONG)

SWITCH

17. Route the switch harness as shown.

SWITCH HARNESS

CLAMPRoute the harnessthrough the clamp.

SWITCH HARNESS

WIRE TIE (Reuse)Secure to thevehicle’s harness.

16. Install the switch as shown.• Tighten the upper bolt first, then tighten the

lower bolt.

SWITCH HARNESS

18. Route the switch harness as shown.

WIRE TIE (Reuse)Secure to the handlebar togetherwith the vehicle’s harness.


19. Route the bullet connector side of the switch harnessto the rear as shown.

SWITCH HARNESS

SWITCH HARNESS

22. Pass battery cable through the terminal boot asshown.• Repeat on the battery cable (red).

23. Install terminal boots at both ends of each power cableas shown.

BULLET CONNECTORS

20. Locate the accessory socket on the right radiator grilland remove the cap as shown. Route the 2P whiteconnector end of the switch harness toward thesocket.

ACCESSORY SOCKET

CAPRemove.

POWER CABLE(Yellow and Blue)

TERMINAL BOOT

BATTERY CABLE (Black)

TERMINAL BOOT

21. Insert the cap into the 2P White connector and connectthe switch harness to the accessory socket as shown.Bundle any excess wire with a wire tie.

2P WHITECONNECTOR

ACCESSORYSOCKET (Black)

CAPInsert.

SWITCH HARNESS

SWITCH HARNESS


24. Loosely install the contactor to the frame as shown.

CONTACTOR

1/4-20 in LOCK NUT

1/4 in FLATWASHER

U-BOLT

25. Connect the battery cables to the corresponding colorterminals on the contactor as shown.

BATTERY CABLE (Red)

BATTERYCABLE (Black)

BATTERY CABLE (Red)


Top view

CONTACTOR

26. Route the battery cables as shown.

FRONT

6 mm NUT

RED

BLUE BLACK

YELLOW

FUSE BOX

6 mm SPRINGWASHER

27. Connect the power cables to the corresponding colorterminals on the contactor as shown..

POWER CABLE (Blue)6 mm NUT

6 mm SPRINGWASHER

POWER CABLE(Yellow)


TERMINAL BOOTCover the connectors.

TERMINAL BOOTCover the connectors.

28. Cover each cable connector with the terminal bootas shown.

29. Connect the contactor harness as shown.

SWITCH HARNESS

CONTACTORHARNESS

CONTACTORPush down the connectedcontactor harness towardthe rear to store it.

30. Rotate the contactor towards the rear as shown andsecure it.• Tighten the 6 mm lock nuts as shown.

6 mm LOCK NUTS

Adjust so that it becomes horizontal.


WIRE TIE (Reuse)Secure both cables.

RIBSecure each cable.

31. Route each power cable as shown. 33. Route the power cables as shown.

32. Route each power cable as shown.

POWER CABLE (Blue)Route along thevehicle’s harness.

POWER CABLE (Yellow)Route along thevehicle’s harness.

POWER CABLE(Blue)

POWER CABLE(Yellow)

SWITCH HARNESS

34. Remove the clips, bolts, and front pipe guardas shown.

CLIP CLIP

SWITCH HARNESSRoute along the vehicle’s harness.

FRONT PIPEGUARD

FLANGE BOLT FLANGE BOLT

RIBSecure each cable.


35. Remove the indicated bolts.

FLANGE BOLTFLANGE BOLT

FLANGE BOLT

WASHER

SKID PLATE

POWER CABLE (Blue)

POWER CABLE (Yellow)

37. Route the power cable as shown.

POWER CABLE(Blue)

POWER CABLE(Yellow)

36. Lower the skid plate as shown.


38. Route the power cables as shown.

POWER CABLE (Blue)


SKID PLATE

SKID PLATE

BOLT

41. Remove the bolts front carrier pipe as shown.

FRONTCARRIER PIPE

BOLT

BOLT(Save)

BOLT(Save)

40. Remove the indicated bolts as shown.• Repeat on the right side.

39. Cut off at the indicated portion of the skidplateas shown.• After cutting, remove any burrs.

POWER CABLE(Blue)


SIDE CUTTERSCut out.


42. Remove the radiator grille under cover as shown.

RADIATOR GRILLEUNDER COVER

43. Assemble the lower mounting bracket as shown.6 x 12 mmFLANGE BOLT

LOWERMOUNTINGBRACKET

SIDEMOUNTINGBRACKET

44. Remove the shipping screw and loosely install theassembled lower mounting bracket onto the winchas shown. 8 x 20 mm BOLT

8 mm FLAT WASHER

SPRING WASHER

LOWER MOUNTINGBRACKET ASSEMBLY

WINCH

WINCH

FRONT CARRIER PIPE

WINCH

45. Place the preassembled winch onto the front carrierpipe at the shown position.

FRONTCARRIER PIPE

SHIPPING SCREW


8 x 30 mmBOLT

FRONT CARRIER PIPE

6.3 mmSPACER

47. Install the upper mounting bracket as shown.

8 x 20 mmBOLT

SPRINGWASHER

9.5 mm SPACER

46. With the winch set, loosely install the front carrier pipeas shown.• Perform this work with two people and support

the winch so that it does not drop down.

8 x 30 mmBOLT 8 mm LOCK NUT

Install the 9.5 mm spacer between frame and uppermounting bracket.• Do the same also on the right side.

8 x 30 mmBOLT

48. Install the roller fairlead as shown.

10 mm SPRING WASHER

10 mm BOLT

10 mm NUTROLLERFAIRLEAD

BOLT

FRONT CARRIER PIPE

8 mm FLATWASHER

8 mm FLATWASHER

8 mm FLATWASHER

8 mm FLAT WASHER

< Upper view >

< Lower view >

ROLLERFAIRLEAD

UPPER MOUNTINGBRACKET


FLANGE NUT POWER CABLE (Blue)

WINCH

51. Connect the yellow power cable as shown.• After connection, cover the cable terminal with

the terminal boot to prevent contact with theframe.

FLANGE NUT

WINCH

49. Install the hook as shown.

COTTER PIN

CLEVIS PIN

ORANGE PULLSTRAP

HOOK

50. Secure the power cables as shown and connect theblue power cable.• After connection, cover the cable terminal with

the terminal boot to prevent contact with theframe.

TERMINAL (Blue)

WIRE TIESecure the powercables to the frame.


POWERCABLE (Yellow)

TERMINAL(Yellow)

COTTER PIN

CLEVIS PIN


CHECK THE SYSTEM:54. Before using the winch, verify the following:

• The wiring to all components is correct. All loose wiresare wrapped tight using cable-ties.

• There are no exposed wires or terminals. Cover anyexposed wires or terminals with terminal boots, heatshrink 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 onthe switch.

SCISSORS

BATTERY COVER

NEGATIVE (-) TERMINAL BATTERY BOLT(Reuse)

POSITIVE (+) TERMINAL

53. Connec t t he b lack ba t te ry cab le to thenegative (-) battery terminal as shown.

55. Install the vehicle’s parts in the reverse order ofremoval.

Cut the positive (+) battery terminal cover as shown.

BATTERY CABLE (Red)


BATTERY BOLT (Reuse)

52. Connect the red battery cable to the positive (+)battery terminal as shown.• After connecting, Cover the connectors.

trx420 winch kit installation...

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