INSTALLATION INSTRUCTIONS ATV WINCH MULTI-MOUNT Multi-Mount Mounting-Kit: PN Application: YAMAHA BIGBEAR 00+

Transcription

1 INSTALLATION INSTRUCTIONS ATV WINCH MULTI-MOUNT Multi-Mount Mounting-Kit: PN Application: YAMAHA BIGBEAR 00+ 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 Winch Operator s Manual, ATV Operator s Manual, and all warning labels before operating the winch and ATV. Stay clear of moving parts and cable. Keep others away when operating the winch. Inspect the winch mechanism, fasteners, and cable, before operating. Replace all worn or damaged parts before operating. Make sure the winch is deactivated when leaving the ATV unattended. PARTS LIST: PART NO. QUANTITY DESCRIPTION mm Lock Washer /16 Nylock Nut /4 Nylock Nut mm Hex Nut #10-32 Nylock Nut /16-18 x 1 Hex Bolt #10 Phillips Head Screw, Black mm-1.25 x 16mm Hex Bolt U-Bolt, Square, 1/4-20 x U-Bolt, 5/16-18 x 1-1/ Multi-Mount Receiver, Front, BigBear Multi-Mount Receiver, Rear, BigBear Frame Strap, MM, BigBear Box Bracket, BigBear TOOLS NEEDED: Ratchet Sockets: 7/16, 1/2, 10mm, 13mm Wrenches: 7/16, 1/2, 13mm Phillips and Flat Blade Screwdrivers WARN INDUSTRIES PAGE Rev D0

2 MULTI-MOUNT HARDWARE INSTALLATION INSTRUCTIONS: REAR-RECEIVER INSTALLATION: The installation of the Rear Multi-Mount Receiver requires relocation of the tool box. The box will be remounted below the Rear Receiver. 1. Use a flat blade screwdriver to remove the push in rivet at the rear of the tool box. Notice: only the expander pin in the center of the rivet should be pried up with the screwdriver. Once the expander pin is pulled out, the rivets should come out of the frame when the box is pushed up. 2. Use a Phillips screwdriver and 10mm socket to remove the fasteners in the side of the tool box. With these fasteners removed, pull the box down from between the frame tubes. 3. Locate the Frame Strap in the kit and position it on top of the frame tubes as shown (Figure 1). Loosely secure the strap to the frame with 5/16 U-Bolts and Nylock Nuts. FRAME STRAP 4. Install the Rear Receiver as shown in Figure 2 by sliding it between the frame tubes from the end of the frame. Locate the Box Bracket and remove the two Box Side Straps by twisting them from the main bracket. Use two (2) 5/16-18 x 1 hex bolts to fasten the Rear Receiver and Box Bracket to the Frame Strap (Figure 2). Install two (2) 1/4-20 x1 Square U-Bolts into the side of the Rear Receiver. Secure the U-Bolts with 1/4 Nylock Nuts. FIGURE 1: Loosely Install Frame Strap 5. Tighten all fasteners to the following specifications: Torque 1/4 Nuts: 5 ft. lb. (7 FIGURE 2: Install Rear Receiver Bracket N m) Torque 5/16 Bolts: 11 ft. lb. (15 N m) WARN INDUSTRIES PAGE Rev D0

3 6. Use an electric drill to drill two 1/4 holes in the back of the tool box in the locations shown (Figure 3). The holes should be located 1-3/4 down from the top of the box and 1/2 and 6-1/2 from the left side of the box. The left side of the box as viewed by the installer looking at the back of the box. 1/2 1-3/4 6-1/2 Drill 1/4 Holes 1-3/4 down from the top of the box. Measure distances shown from muffler side of Box. BOX SIDE STRAPS FIGURE 3: Drill 1/4 Holes in Back of Box FIGURE 4: Install Box Side Straps 7. Install the Box Side Straps on the original box mounting tabs on the frame (Figure 4). Use the two small Black Phillips Head screws provided and #10-32 Nylock Nuts to secure the straps as shown. The heads of the screws should be toward the inside the frame. 8. Install the tool box on the Box Bracket and Box Side Straps. Use the original tool box fasteners in the sides of the box and two Black Phillips Head screws in the back of the box. FRONT-RECEIVER INSTALLATION: 1. Install the Front Receiver in position as shown in Figure 5. The frame and front bumper should have mounting tabs to mount the Front Receiver on. Use four (4) 8mm-1.25 x 16mm Hex Bolts, 8mm Lock Washers, and 8mm Hex nuts to secure the Front Receiver to the mounting tabs. The Front Receiver tube should extend between the front bumper and pass over the skidpan. Torque 8mm Bolts: 17 ft. lb. (23 N m) FIGURE 5: Install Front Receiver with 8mm Bolts WARN INDUSTRIES PAGE Rev D0

4 WINCH-CARRIER PLATE INSTALLATION: 1. Attach the WARN winch and the associated fairlead to the WINCH-CARRIER PLATE, using the fasteners that were included with the winch. Make sure that the 5/16-18 bolts that attach the winch to the WINCH-CARRIER PLATE are torque to an approximately 20 ft-lbs. 2. Install the WINCH-CARRIER PLATE into the rear-receiver and secure with a HITCH-PIN and CLIP. CAUTION: It is recommended that the winch is stored in the rear-receiver when it is not in use. Because, it has been determined that the winch is less likely to be damaged while it is stored in the rear than in the front receiver, because the winch tends to stick-out and is not as protected as in the permanentlymounted-winch systems. CONTACTOR INSTALLATION: 3. It is recommended that you install the contactor in a dry and clean location on the bike. The best location would be inside the rear storage box or under the seat, away from dirt and rain. 4. Refer to the WINCH OPERATOR S MANUAL for remote socket installation. 5. Before proceeding, refer to the WINCH OPERATOR S MANUAL for contactor installation. After the wiring has been properly routed through the ATV, the wires going to the contactor must be installed a certain way. The wires going from the battery to the terminals on the contactor are straightforward, but the wires going from the red quick-disconnects to the terminals on the contactor must be orientated a certain way prior to being connected to the contactor (Figure 6). Place the black rubber boot on both wires (one 48in and the other 96in). The terminals of each of these two wires must be orientated such that they are back-to-back as shown in the Figure 6 below. With the wires positioned as shown, use a 13mm wrench to tighten the terminal bolt. Finally, place the black rubber boot over both terminals and post. TO MOTOR TERMINAL NO.1 (YELLOW) TO POSITIVE (+) BATTERY TERMINAL (RED) TO MOTOR TERMINAL NO. 2 (BLUE) TO NEGATIVE (-) BATTERY TERMINAL (BLACK) TERMINALS BACK TO BACK ON CONTACTOR POST FIGURE 6 WARN INDUSTRIES PAGE Rev D0

5 NOTICE: There are two wire terminals that must go to each of the contactor posts as shown, as there will be two wires for motor-terminal 1 and two wires for motor-terminal 2. One set going to the front of the ATV (red connector) and the other set going to the rear of the bike (red connector). 6. Refer to the WINCH OPERATOR S MANUAL for full and complete details on wiring installation. CAUTION: The hook ( or toe-strap, etc.) should NEVER be hooked into either of the handles of the winch-carrierplate. This will cause permanent damage to the winch-carrier-plate. WARN INDUSTRIES PAGE Rev D0