Kolpin Outdoors 25-1200 Installation and operating instructions

© 2019 Kolpin Outdoors Inc. REV 04
WINCH MOUNT KIT
FOR HONDA FOREMAN 500 / RUBICON 500
P/N 25-1200
ASSEMBLY / OWNERS MANUAL
Application
WINCH KI NO. 25-9xxx
Before you begin, please read these instructions and check to be sure all parts and tools are
accounted for. he following instructions contain details required to install and service the contents
of this kit.

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© 2019 Kolpin Outdoors Inc. REV 04
OPERATING INSTRUCTIONS
Congratulations! You’ve just purchased the most durable accessory component in the industry. Our accessories work great all year
round! With proper care and maintenance, your Kolpin accessory will last for years to come! Please read and understand all assembly
instructions, notices and warnings before assembling and using your Kolpin accessory.
Follow t ese guidelines to ensure a successful and satisfactory installation:
Read, understand this manual before beginning installation
Periodically check for wear and tightness of all fasteners.
Replace or re-torque fasteners as necessary.
SAFETY & GENERAL PRODUCT INFORMATION
Kolpin accessories are designed with your safety in mind.
In order to protect you and your vehicle, certain parts of the accessory and/or hardware may be designed to collapse or break when
the equipment is over-stressed.
Kolpin winch mount kits are designed to be compatible with Kolpin and Cycle Country winches along with many others, but may not
be compatible with some winches. Kolpin winch mount kits have design features that benefit snow plow applications.
! DANGER ! ! WARNING ! ! CAUTION !
To avoid personal injury or damage to your ve icle:
Read and understand all notices for:
Caution
Warning
Danger
Follow instructions for your vehicle, winch, winch mount and other items used in combination with this product.
Do not winch unsecured loads at any time.
Disconnect battery during winch installation or service to prevent electrical hazards.
Do not lift loads overhead.
Do not exceed the load capacity of the winch.
Always wear gloves when handling wire winch cable.
Do not use your winch or winch mount for towing.
Do not shock load the winch, cable or winch mount.
Keep fingers, hands and loose clothing away from roller fairlead and winch cable drum when in use.

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© 2019 Kolpin Outdoors Inc. REV 04
Kit Contents:
Item Qty Part Description Part Number
11Foreman Rubicon Winch Mount Plate -
22Steel Bushing Spacer 7/8” -
42Flat Washer, Zinc Plated, M6 -
52Flat Washer, Zinc Plated, M8 -
64Locknut, Zinc Plated, M6-1.0 -
32Round U-Bolt, Zinc Plated, M6-1.0 x 30mm x 50mm -
7 2Hex Bolt, Zinc Plated, M8-1.25 x 25mm LG -
8 1Instruction Guide (not shown) -

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© 2019 Kolpin Outdoors Inc. REV 04
BEFORE YOU BEGIN:
•Your Kolpin accessory is exclusively designed for
your ve icle
• Please read and understand all instructions
• Verify all parts and tools are accounted for
• To ensure a satisfactory installation, follow all steps
correctly and in t e sequence described
• Keep t ese instructions for future reference or for
informational requests
• To facilitate installation, make sure t at your ve icle
is clean and free of debris
• All directions referring to rig t and left are w en t e
rider is sitting on t e mac ine
TOOLS REQUIRED:
• Basic Metric Wrenc and Socket Set
• Pliers
• Do not use impact tools to install ardware
APPROXIMATE ASSEMBLY TIME: 30 minutes
Note: If any hardware is missing, do not return to the store. Call
us to help, oll Free 1-877-956-5746.
SPARE KITS Hardware kit
P/N CYC1982
Item Description
2Steel Bushing Spacer 7/8” 2x
3Round U-Bolt, Zinc Plated, M6-1.0 x 30mm x 50mm 2x
4Flat Washer, Zinc Plated, M6 2x
5Flat Washer, Zinc Plated, M8 2x
6Locknut, Zinc Plated, M6-1.0 4x
7Hex Bolt, Zinc Plated, M8-1.25 x 25mm LG 2x

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© 2019 Kolpin Outdoors Inc. REV 04
Mount Plate Installation:
1.Remove the bumper cover and lower rock guard
from the A V as shown. (See illustration 1-1).
2. Remove the two OEM bumper bolts located on the
upper portion of the frame as shown. (See illustra-
tion 1-2). Note, the OEM bolts will not be re-used
to install the winch mount plate.
3. Place the winch mount plate (item #1) on the frame
supports as shown in illustration 1-2. Insert winch
mount at an angle through the front of the frame,
then place on top of bumper supports. (See
illustrations 1-3 and 1-4).
Ill. 1-1
Ill. 1-2
Ill. 1-3
Rock Guard
Bumper Cover
Honda Foreman/
Rubicon Frame
OEM
Fasteners
#1
Ill. 1-4
#1

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© 2019 Kolpin Outdoors Inc. REV 04
Mount Plate Installation (continued):
4. Place bushings (item #2) between the left and right
bumper support mount holes and the winch mount.
Place M8 washers (item #5) over the mount holes
and fasten with M8 metric bolts (item #7) as shown.
(See illustration 1-5).
Note, do not tighten the
fasteners at this time.
5. Install u-bolts (item #3) around the bumper frame
and through the front mount holes. Place M6
washers (item #4) over the slotted holes and fasten
with M6 locknuts (item #6).
6. orque all mount fasteners to specifications.
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
Ill. 1-6
Ill. 1-5
#2
#5
#7
6MM FASTENER TORQUE:
7 ft. lbs. (9.5 Nm)
#3
#4
#6

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© 2019 Kolpin Outdoors Inc. REV 04
Roller Fairlead Installation:
7. Install winch and roller fairlead per the instructions
that came with the kit. Use fasteners included with
winch kit to secure the fairlead to the winch mount.
ighten to M8 specification. (See illustration 1-7).
8. Re-install the OEM bumper cover and rock guard.
ighten fasteners to manufacture specifications. (See
illustration 1-8).
Winc Wiring and Connections:
9. Using the winch kit instructions, route and connect
the electrical cables and components for the winch
system.
10. Secure all harnesses using cable ties (provided with
winch kit) to prevent contact with hot components,
sharp edges or moving parts.
11. Reconnect red positive (+) cable and black negative
(-) cable to battery.
12. With the vehicle key in the ON position, check winch
for proper operation.
13. Retighten all hardware after 30 minutes of riding.
Ill. 1-7
Ill. 1-8
Components
supplied with
winch kit
Components
supplied with
winch kit
Components
supplied with
winch kit
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
Rock Guard
Bumper Cover Honda Foreman/
Rubicon Frame

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© 2019 Kolpin Outdoors Inc. REV 04
One Year Limited Warranty
For the period of one (1) year from the purchase date, Kolpin will replace for the original purchaser,
free of charge, any part or parts found upon examination by Kolpin to be defective in material,
workmanship, or both.
All transportation costs incurred submitting product to Kolpin for warranty consideration must be
borne by the purchaser. If Kolpin determines that the product must be returned to the factory for
credit, please call 1-877-956-5746 for a Return Merchandise Authorization (RMA) number and
shipping instructions.
his warranty does not apply to parts that have been damaged by accident, alteration, abuse,
improper maintenance, normal wear, or other causes beyond the manufacturer’s control. In order to
protect you and your A V, certain parts of the accessory system and/or hardware are designed to
fail when the equipment is over-stressed. Parts that are lost due to loosening and improper
maintenance are not covered under warranty. his warranty does not cover removal or reinstallation
labor fees of the plow system and related components.
Peripheral products such as engines, electric motors, and actuators may carry an original
manufacturer’s warranty. Most hardware is general in nature and is easily obtained locally. Be sure
to replace with minimum metric class 8.8 specification.
Kolpin Outdoors, Inc.
Telep one: (763)-478-5800
Toll Free: (877)-956-5746
Fax Number: (800)-245-7569
www.kolpin.com
Email: customers[email protected]