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WARN® INDUSTRIES

PAGE 1

80912A0

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.

INSTALLATION INSTRUCTIONS

ATV Front Plow Mount Kit

Part  Number:

80554

Applications:

2005-2009 Honda Foreman 500
2005-2009 Honda Foreman ES 500
2005-2008 Honda Rubicon 500

 

WARNING

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other

objects are not punctured or damaged when/if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides
of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may
result in vehicle damage, electrical shock, fire or personal injury.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause

eye injury.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys use extreme caution when cutting and trimming during fitting.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys remove jewelry and wear eye protection.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er lean over battery while making connections.

‰

Ne

Ne

Ne

Ne

Nevvvvver r

er r

er r

er r

er rout

out

out

out

oute electrical cables:

e electrical cables:

e electrical cables:

e electrical cables:

e electrical cables:

o

Across any sharp edges.

o

Through or near moving parts.

o

Near parts that become hot.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

ys

ys

ys

ys insulate and protect all exposed wiring and electrical terminals.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

ys

ys

ys

ys install terminal boots as directed in installation instructions.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys use appropriate and adequate care in lifting components into place.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys insure components will remain secure during installation and operation.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys tighten all nuts and bolts securely, per the installation instructions.

‰

Alw

Alw

Alw

Alw

Alwaaaaays

ys

ys

ys

ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er operate the vehicle on slopes greater than 10 degrees with the plow installed.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er stand or ride on the plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys replace all worn or damaged parts before operating.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er operate this WARN product with damaged or missing parts.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys drive slowly over bumpy and rough terrain. Driving at speeds that cause the plow to bounce while in the up position

can cause the winch to back-drive, causing the plow to work its way down. This may result in the plow impacting a stationary
object and cause damage to the vehicle and operator injury or death.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious

damage to the ATV if the plow is raised too high. The plow blade will drop suddenly if the j-bolt breaks, so always be sure
there are no bystanders when you raise and lower the plow.

‰

Ne

Ne

Ne

Ne

Nevvvvver 

er 

er 

er 

er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

‰

Alw

Alw

Alw

Alw

Alwaaaaays 

ys 

ys 

ys 

ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.

INJURY HAZARD

Failure to observe these instructions could lead to severe injury or death.

Содержание 80554

Страница 1: ...electrical cables o Across any sharp edges o Through or near moving parts o Near parts that become hot Alw Alw Alw Alw Alwa a a a ays ys ys ys ys insulate and protect all exposed wiring and electrical terminals Alw Alw Alw Alw Alwa a a a ays ys ys ys ys install terminal boots as directed in installation instructions Alw Alw Alw Alw Alwa a a a ays ys ys ys ys use appropriate and adequate care in li...

Страница 2: ...or or moderat o minor or moderat o minor or moderat o minor or moderate injur e injur e injur e injur e injury y y y y Always take time to fully read and understand the installation and Operations Guide included with this product Never operate this product if you are under 16 years of age Never operate this product when under the influence of drugs alcohol or medications Read installation and oper...

Страница 3: ...t 5 16 18x1 1 4x1 3 4 4 B2 1324 5 16 flat washer 8 B3 2002 5 16 18 lock nut 8 C1 79712 3 8 Safety Retaining Clip 2 D1 79340 RH Bolt On Offset Weldment 1 D2 79341 LH Bolt On Offset Weldment 1 III Torque Specifications 1 4 6mm 8 lb ft 10 8 N m 5 16 8mm 17 lb ft 22 5 N m 3 8 10mm 30 lb ft 40 7 N m 7 16 11mm 50 lb ft 67 8 N m 1 2 12mm 75 lb ft 101 7 N m A1 B1 B2 B3 C1 C1 B2 B3 D2 D1 ...

Страница 4: ...front plow mount can be installed along with existing winch mount and body armor kits 2 Slide front plow mount through vehicle frame in orientation as shown in Figure 2 Rotate the mount as required to provide adequate clearance 3 Slide u bolts around vehicle frame tube and through back side of plow mount as shown in Figure 3 Figure 1 Figure 3 Figure 2 ...

Страница 5: ...ratchet will provide better access to mounting hardware 5 Figure 5 shows a completed installation with front plow mount bolted in place 6 Bolt on right hand and left hand offset tab weldments to push tube base in orientation shown in Figure on page 3 Hardware is supplied with the plow kit Torque hardware to specification once proper fit has been verified with vehicle plow mount IV Foreman Installa...

Страница 6: ... 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 READ THE VEHICLE S OPERATOR MANUAL WINCH OPERATOR MANUAL AND ALL WARN ING LABELS PRI...

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