installation instructions

Accessory
INSTALLATION
INSTRUCTIONS
Application
After ‘16
SXS1000M3/M3P/M3LE
SXS1000M5P/M5D/M5LE
WINCH MOUNT
P/N 08L73-HL4-F01
PARTS LIST
(1)
(27)
(26)
(28)
(22)
(4)
(21)
(9)
(6)
(15)
(13)
(12)
(7)
(20)
(14)
(25)
(8)
(10)
(23)
(19)
(16)
(24)
(18)
(11)
(3)
(17)
(2)
(B, C)
(5)
© 2017 American Honda Motor Co., Inc. - All Rights Reserved.
Publication No.
MII 16083
Issue Date
February 2017
No.
Description
Qty
(1)
Installation Instructions URL
1
(2)
Winch power cables*
1
(3)
Winch battery cable
1
(4)
Remote control sub harness
1
(5)
Winch sub harness
1
(6)
Wire tie
19
(7)
Clip band
1
(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
(15)
Lock washer (small)
2
(16)
6 mm flange bolt
2
(17)
5 mm shoulder bolt
2
(18)
Rubber washer
2
(19)
5 mm flange nut
2
(20)
Winch bracket
1
(21)
10 mm flange nut
2
(22)
10 mm flange bolt
2
(23)
Lock washer (large)
4
(24)
8 mm bolt
4
(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.
• If your winch power cables have five clip bands,
bands B and C (indicated in the illustration), will not
be used for installation.
1 of 18
08L72-HL4-F01
WINCH KIT
Sold separately
CUSTOMER INFORMATION:
(12)
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.”
(10)
(7)
(11)
BEFORE YOU BEGIN
(1)
(8)
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.
Not used.
TOOLS AND SUPPLIES REQUIRED
Socket (8, 10, 12 and 14 mm)
Ratchet
Box-end wrench (8, 10 and 14 mm)
Side cutters
Electric drill
Drill bit (5 and 7 mm)
Holesaw (18 mm)
Marker
Ruler
Electrical tape
Scissors
Wire or Wire tie (Length: 290 mm or more/Width: 5 mm)
Torque wrench
(2)
(9)
(3)
(5)
(4)
(15)
(14)
(13)
(6)
TORQUE CHART
No.
Description
Tighten all screws, bolts, and nuts to their specified
torque values. Refer to the Service Manual for the torque
values of the removed parts.
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
(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
Item
2 of 18
N·m
kgf·m
Ibf·ft
5 mm bolt and nut
5.2
0.5
3.8
5 mm flange nut
5.2
0.5
3.8
6 mm nut
10
1.0
7
6 mm flange bolt and nut
12
1.2
9
8 mm bolt
22
2.2
16
8 mm flange bolt
27
2.8
20
10 mm flange nut
39
4.0
29
10 mm bolt washer
50
5.1
37
1.
MAXIMUM WINCH CAPACITY
Winch Capacity
Remove the vehicle’s parts as shown.
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
3.
Remove the front hood as shown.
6.
7.
Tighten the loosely installed parts securely.
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.
INSTRUMENT PANEL
(BACK SIDE)
RIGHT ROLLER
BRACKET
LEFT ROLLER
BRACKET
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
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)
WASHER
5 mm BOLT
INSTRUMENT PANEL
(BACK SIDE)
MARK
REMOTE CONTROL
SUB HARNESS
ELECTRIC DRILL
(5 mm BIT)
10. Open the glove box and pass the remote control sub
harness through the hole in the instrument panel.
LOCK
WASHER
(small)
5 mm NUT
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
13. Install the contactor to the contactor stay as shown.
15. Route and connect the winch sub harness to the
accessory socket as shown.
5 mm FLANGE NUT
WINCH SUB HARNESS
CONTACTOR STAY
5 mm
SHOULDER
BOLT
CONTACTOR
RUBBER WASHER
ACCESSORY
SOCKET
14. Install the assembled contactor to the front fender as
shown.
2-PIN WATERPROOF
CONNECTOR (Black)
16. Connect the vehicle’s harness to the winch sub
harness as shown.
6 mm FLANGE BOLT
WINCH SUB HARNESS
ASSEMBLED
CONTACTOR
2-PIN WATERPROOF
CONNECTOR (Black)
FRONT FENDER
CONTACTOR
PLATE NUT
VEHICLE’S HARNESS
When also installing the Horn mount:
HORN SUB
HARNESS
2-PIN
WATERPROOF
CONNECTOR
(Black)
WINCH SUB HARNESS
2-PIN
WATERPROOF
CONNECTOR
(Black)
OPENED HOLE
VEHICLE’S HARNESS
6 of 18
17. Secure the winch sub harness with the wire tie as
shown.
19. Secure the harnesses with the wire ties as shown.
REMOTE
CONTROL SUB
HARNESS
WINCH SUB HARNESS
3-PIN WATERPROOF
CONNECTOR (White)
WINCH SUB HARNESS
WIRE TIE
Secure remote control sub
harness to the vehicle’s
harness.
WIRE TIE
Secure the winch
sub harness to the
vehicle’s harness.
20. Remove the bolt as shown.
<Right side>
18. Connect the winch sub harness and remote control
sub harness as shown.
REMOTE CONTROL
SUB HARNESS
3-PIN WATERPROOF
CONNECTOR (White)
WINCH SUB
HARNESS
BOLT
REMOTE CONTROL
SUB HARNESS
RUBBER
7 of 18
WIRE TIE
Secure winch sub
harness to the vehicle’s
harness.
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)
WINCH POWER CABLES
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
ASSEMBLED HORN
6 mm FLANGE BOLT
Included in the Horn mount.
22. Install the winch power cables as shown.
WINCH POWER CABLES
CLIP BAND
HARNESS CLIP STAY
8 of 18
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.
CLIP BAND
WINCH POWER CABLES
27. Route the winch power cables and secure them with
the wire tie as shown.
WIRE TIE
Secure the winch power
cables to the frame.
WINCH POWER CABLES
9 of 18
29. Install the terminal boots as shown.
31. Install the winch to the winch bracket as shown.
WINCH
WINCH POWER CABLES
TERMINAL BOOT
Pass the winch power
cables through.
WINCH BRACKET
WINCH POWER CABLES
LOCK
WASHER
(large)
8 mm BOLT
Pull out the wire over the bracket as shown.
30. Remove the wire tie as shown.
WIRE TIE
Remove.
WINCH BRACKET
WIRE
WINCH
10 of 18
32. Loosely install the assembled winch as shown.
34. Remove the blue tape from the factory installed
winch ground cable. Remove the indicated clip band
from the front fender.
<Front side>
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.
WINCH POWER CABLES
WINCH POWER CABLES
TAPE
(Yellow)
TAPE (Blue)
6 mm FLANGE
NUT
Included in
the Winch kit.
ASSEMBLED
WINCH
6 mm FLANGE NUT
Included in the Winch kit.
11 of 18
36. Route the winch sub harness along the main
harness as shown.
38. Install the terminal boots as shown.
WINCH POWER CABLES
WINCH SUB HARNESS
TERMINAL BOOT
Pass the winch power
cables through.
WINCH POWER CABLES
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.
CONTACTOR
CONTACTOR
WINCH POWER CABLE
6 mm NUT
WINCH POWER CABLE
LOCK WASHER
Included in the
Winch kit.
WINCH POWER CABLES
TAPE
(Yellow)
CONTACTOR
12 of 18
TAPE (Blue)
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
VEHICLE’S
HARNESS
STARTER RELAY
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
44. Install the terminal boot as shown.
46. Install the terminal boot as shown.
WINCH GROUND CABLE
WINCH BATTERY CABLE
TERMINAL BOOT
Pass the winch ground
cable through.
TERMINAL BOOT
Pass the winch battery
cable through.
WINCH GROUND
CABLE
WINCH
BATTERY CABLE
45. Install the winch battery cable as shown.
47. Install the winch ground cable as shown.
Install in the direction as shown.
Install in the direction as shown.
WINCH
BATTERY
CABLE
WINCH
GROUND
CABLE
CONTACTOR
6 mm NUT
CONTACTOR
LOCK WASHER
Included in the
Winch kit.
6 mm NUT
LOCK WASHER
Included in the
Winch kit.
WINCH
BATTERY CABLE
CONTACTOR
CONTACTOR
14 of 18
WINCH
GROUND
CABLE
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.
WINCH SUB HARNESS
CONTACTOR COVER
FRONT FENDER
CLIP BAND
OPEN
HOLE
CONTACTOR
51. Secure the winch ground cable and sub harness
with the wire tie as shown.
WINCH GROUND WIRE TIE
Secure the winch
CABLE
ground cable and
WINCH SUB HARNESS
winch sub harness
to the vehicle’s
harness.
15 of 18
52. Secure the winch sub harness with the wire ties as
shown.
WINCH SUB
HARNESS
54. Remove the loosely installed bolts.
• Repeat on the right side.
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)
WINCH BRACKET
BOLT
(Reuse)
10 mm BOLT WASHER
Do not install when the
vehicle is equipped
with the plow.
WIRE
16 of 18
ROLLER
FAIRLEAD
56. Install the hook and strap as shown.
57. Connect the remote control switch as shown.
<Front side>
<Right side>
After connecting, put the remote control switch in the
glove box as shown.
COTTER PIN
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
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
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