Warn 104300 User manual

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WARN INDUSTRIES, INC. 12900 S.E. Capps Road,
Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: [phone]
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
International Sales/Customer Service: 1-503-722-3008
International Fax: [phone]
INSTALLATION INSTRUCTIONS
MOUNTING KIT BUMPER
Part Number: 104300
Application: 2019 Honda Talon
GENERAL SAFETY PRECAUTIONS
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 identies 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
Impact and Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH
• Always KnowYourWinch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide toWinchingTechniques, in order to understand your winch and its operations.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Never use a jack to support the vehicle.
• Always use jack stands in pairs to support the vehicle.
• Always use jacks or jack stands only on a hard, stable, and level surface.
• Never exceed the rated capacity of a jack or jack stands.
• Always verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle.
• Never work under vehicle before properly securing vehicle.
• Always use appropriate and adequate care in lifting components into place.
• Always insure components will remain secure during installation and operation.
• Always tighten all nuts and bolts securely, per the installation and operation.
• Always perform regular inspections and maintenance on the winch, winch mount and related hardware.
• Always replace all worn or damaged parts before operating.
• Never operate thisWARN product with damaged or missing parts.
• Always 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, re or personal injury.
• Always use extreme caution when cutting and trimming during tting.
• Always wear safety glasses when installing this kit. A drilling operation will cause ying metal chips. Flying chips can cause eye injury.
• Always remove jewelry and wear eye protection.
• Never lean over battery while making connections.
• Never route electrical cables across any sharp edge, through or near moving parts, near parts that become hot.
Read installation and operating instructions thoroughly.

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TABLE OF CONTENTS
Tools Required.........................................................................................................................................................................................................................page 2
Torque Specications............................................................................................................................................................................................................page 2
Parts List.....................................................................................................................................................................................................................................page 3
Installation ............................................................................................................................................................................................................................page 4-6Maintenance/Care..................................................................................................................................................................................................................page 6CAUTION
Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO MINOR OR MODERATE INJURY
• Part edges may be sharp!
• Always use proper posture / lifting technique or get lifting assistance while handling and installing product.
Read installation and operating instructions thoroughly.
TOOLS REQUIRED
- Standard and Metric wrenches
- Standard and Metric sockets
- Ratchet
- Extension
- Cutting tool
TORQUE SPECIFICATIONS
Please use the recommended torque specications when assembling this product unless otherwise specied in the instructions.
FASTENER SIZE FASTENER TORQUE FASTENER SIZE FASTENER TORQUE
lb-ft (N.m) lb-ft (N.m)
1/4" 8 (11) M4 (2) 3
5/16" 17 (23) M5 (4.5) 6
3/8" 30 (40) M6 (7.5) 10
7/16” 48 (66) M8 (18) 25
1/2" 74 (100) M10 (37) 50
9/16” 106 (144)
5/8" 148 (200)
3/4” 269 (364)

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PARTS LIST
Part Number Qty Description
A1 1 BUMPER SHELL
A2 1 FAIRLEAD PLATE
A3 1 UPPER BUMPER MOUNT
A4 1 SKID PLATE
A5 1 LIGHT BRACKET
B1 19 M8 X 25MM HEX HEAD BOLT
B2 28 FLAT WASHER
B3 11 M8 LOCK NUT
B4 2 PLASTIC WASHER
A1
A2
B1
B2
B3
A3
A4
B4
A5
INSTALLATION INSTRUCTIONS
Figure 1

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INSTALLATION INSTRUCTIONS
1. Remove the bumper by removing the two torx head screws,
two upper bolts and one lower from each side of vehicle.
Retain hardware.
2. Slide bumper forward while carefully leveraging the plastic
out of the way.
3. Line up the new bumper mount (A3) with the stock bumper
mounting location.
4. Install one M8 bolts (B1) with washer (B2) through the top
two mounting holes (each side).
5. Insert one M8 bolt (B1) through bottom mounting hole
(each side). NOTE: This is to help hold mount up in place
and will be removed in a later step.
6. Secure upper bolts with one washer (B2) and lock nut
(B3) (each side). NOTE: Tighten only the upper two bolts,
washers and locknuts at this time.
5. Cut the plastic along the white line shown in the photo
(each side).
6. Install one factory torx head screw through plastic, upper
mounting bracket and frame (each side).
7. Remove the lower mounting bolt (each side).
Torx head
screws
Remove
Remove
Cut plastic
B1, B2 and
B3
B1
Figure 2
Figure 3
Figure 4
Torx head
screw
Lower mounting
bolt

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INSTALLATION INSTRUCTIONS
8. Slide the skid plate (A4) into place. NOTE: The tabs on the
skid plate will t in between the bumper mount and the
vehicle frame.
9. Install one M8 bolt (B1) and washer (B2) to lower mounting
location.
10. If you have a light bar, install light bar to light bracket (A5)
now.
11. Install light bracket to bumper mount using two supplied
M8 bolts (B1), four washers (B2) and two nuts (B3). Refer to
exploded view on page 3.
12. While lifting up on the skid plate, slide the bumper shell
(A1) over the upper mounting bracket. NOTE: The skid
plate should t on the inside edge of the bumper shell.
13. Install one M8 bolt (B1) and one at washer (B2) through
the lower bumper end cap mounting hole. Do not continue
all the way through the skid plate yet.
14. Insert one plastic washer (B4) over bolt. NOTE: The plastic
washer sits in between the end cap and the skid plate. Trim
any excess o washer if necessary.
15. Continue threading bolt through skid plate and fasten with
lock nut (B3). Refer to exploded view on page 3.
16. Repeat for other side.
B1 and B2
A4
A1
Figure 5
Figure 6
Install light
bracket here
Figure 7
B1, B2, B4, B3

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INSTALLATION INSTRUCTIONS
17. Install three M8 bolts (B1) and washer (B2) through the skid
plate and bumper shell mounting holes. Secure with three
washers (B2) and lock nuts (B3).
18. Install your fairlead to your fairlead plate (A2) using
hardware in your winch kit.
19. Line up fairlead plate with mounting holes on top of
bumper mount.
20. Place the winch on top of the fairlead plate.
21. For ease of installation, we recommend attaching your
power cables to your winch before installing the winch
to the bumper mount. Follow your wiring installation
instructions found with your winch.
22. Reach in through the side or the rear of the bumper and
thread the four LONGER M8 bolts supplied in this kit, up
through bumper mount, fairlead plate and into winch feet.
WARNING
Do not use the M8 bolts supplied in your winch kit, they will
not be long enough.
23. Torque all hardware per recommendations on page 3.
B1, B2, B3
Figure 8
Figure 9
Figure 10
MAINTENANCE / CARE
1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that appears rusted or
deformed.
2. Inspect all nuts and bolts on the winch, winch mount,, and related hardware prior to each use. Tighten all nuts that appear to be
loose. Stripped, fractured, or bent bolts or nuts need to be replaced.
3. Check all cables prior to use. Replace cables that look worn or frayed.
4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.