KFI HK-321 User manual

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©2015 Copyright Kappers Fabricating, Inc. All rights reserved
2016 Honda Pioneer 1000
Winch Mount PART # 101285
Hardware Kit: HK-321
HK-031
Kit Components:
Qty. PartDescription:
1.................WinchMountPlate
1.................WinchMountSupportBracket
1.................FairleadConverterMountPlate
4.................M10-1.25X30MMHexBoltFineThreadGR8.8Zinc
4.................M10FlatWasherZinc
4.................M10LockWasherZinc
1.................3/8”-16 X 3/4” Hex Flanged Bolt GR5 Steel Zinc
1.................3/8”-16 Hex Flanged Nylock Nut GR5 Steel Zinc
2.................#4-40X1.50”Screw
2.................#4-40NylockNut
2.................#6FlatWasher
2.................3/16”FenderWasher
1. Startbyremovingthetwocapscrews(A)
holdingtheplastictothebumperoneachside.
Removethetwobolts(B)onthebottomof
thebumperasshowninFigure 2&3,andthe
fourbolts(C)inthebumpertube(asshownin
Figure 3).
INSTALLATION INSTRUCTIONS:
“Figure 2” Bumper bolt location
“Figure 3” Bumper bolt location
“Figure 1” Exploded view
cc

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©2015 Copyright Kappers Fabricating, Inc. All rights reserved
“Figure 5” Mount support bracket attached with supplied hardware
“Figure 6” Attach winch leads, attach winch to Mount Plate
“Figure 7” Attach Mount plate & winch assembly to the support
bracket
D
“Figure 4” Differential bolts
2. Removethetwoboltsfromthedifferential
bracketasshowninFigure 4.Assemblethe
bottomwinchmountsupportbracketasshown
inFigure 5withthesuppliedM10bolts,
washers,andlockwashersshowningure1.
Tightentheseboltsasyouwillnothaveaccess
tothemafterthewinchandwinchmountare
asembledandinplace.
3. Connectthewinchcables(longerwires,
typicallyblueandyellow)tothewinchleads
beforemountingtothewinchmountplateas
showninFigure 6. NOTE: If winch termi-
nals come close to hitting the frame, you
might have to rotate end cap and motor
housing 90 degrees.
4. Attachyourwinchtothewinchmountbracket
withtheshorterhardwaresuppliedwithyour
winch.Only attach the rear bolts!
Tightentheseboltsasyouwillnothaveaccess
tothemafterthewinchandwinchmountare
assembledandinplace.
Standard
Wide
Two-hole
Winch Bolt Layout
EE
5. Placethewinchassemblyintothelocation
asshowninFigure 7ontopofthesupport
bracket.TemporarilyplacesuppliedM10Bolts
(D)throughthemountlooselytoassurecorrect
allignmentasshowninFigure 7.Finishattach-
ingyourwinchwiththelongerhardwaresup-
pliedwithyourwinchthroughthetwowinch
plates.Tightenthesetwobolts(E).Remove
theM10bolts(D)youwillneedthesewhen
re-installingthebumper.

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©2015 Copyright Kappers Fabricating, Inc. All rights reserved
“Figure 9” Fairlead install (Standard Fairlead)
“Figure 8” Fairlead Mount Plate install (Standard Fairlead)
“Figure 10” Fairlead install (Wide Fairlead)
6. Attach Fairlead to the front bumper.
Standard Fairlead 4.875” bolt pattern -
First attach the Fairlead convertor mount
plate with the 3/8”-16 nut and bolt on the
passenger side as shown in Figure 8. Attach
your Fairlead to the mounting plate as shown
in Figure 9 with the hardware included with
your winch.
Wide Fairlead 6.00” bolt pattern -
Attach your fairlead directly to the bumper
as shown in Figure 10 using the hardware
included with your winch.
7. Rotate the clutch cap on your winch to the
“Free Spool” position and pull 2-3 feet of cable
out. Feed the cable through the fairlead mount-
ed to your bumper.
8. Re-install the front bumper. Refer to step 1 for
bolt locations. You will use bolts (D) provided
with your winch mount in place of the stock
bolt (B) previously removed. You will use
the rest of the stock hardware to re-install the
bumper.

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©2015 Copyright Kappers Fabricating, Inc. All rights reserved
1. Tomakeroutingwiresandinstallingyour
contactoreasier,temporarilyrepositionthe
coolantoverowtankbylifting/pullingitupto
popitoutofitshangingbracket.(seeFigure 11)
2. MountContactor.SeeFigure 11 & 12for
suggestedlocation.Markholesoutanddrill.
Attachcontactorusinghardwaresuppliedwith
yourwinch.
3. RockerSwitch-red/powerwire-
-Unclip the fuse panel from the body (see Figure
11 & 14 for location). Locate the White wire with
Black stripe next to the heavy red power wire as
shown in Figure 13. Note: The ignition controlled
accessory wire may be red with a black stripe on
some machines. Verify you have the correct wire by
using a test light. Test light should only illuminate
when key is on.
-Connecttheredwirefromyourrockerswitchtothe
whitewithblackstripeignitioncontrolledaccessory
wireusingthesuppliedquickconnectororother
means.(as shown in Figure 13)

4.Use the wiring instructions in your winch manual
and finish wiring accordingly.
WIRING INSTRUCTIONS:
“Figure 12” Contactor installation
“Figure 11” Coolant overow tank location & suggested
contactor location
“Figure 14” Winch cables routed to contactor
“Figure 13” Accessory wire location
White / Black wire
Red / Black wire
Red Wire
Fuse Panel
Access
Hole
Fuse Panel
Coolant Overflow
Tank