Warn 80554 User manual

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
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ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
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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.
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ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause
eye injury.
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ys use extreme caution when cutting and trimming during fitting.
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ys remove jewelry and wear eye protection.
NeNe
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er lean over battery while making connections.
NeNe
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ver rer r
er rer r
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oute electrical cables:e electrical cables:
e electrical cables:e electrical cables:
e electrical cables:
oAcross any sharp edges.
oThrough or near moving parts.
oNear parts that become hot.
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ys insulate and protect all exposed wiring and electrical terminals.
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ys install terminal boots as directed in installation instructions.
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ys use appropriate and adequate care in lifting components into place.
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ys insure components will remain secure during installation and operation.
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ys tighten all nuts and bolts securely, per the installation instructions.
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ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
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ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
NeNe
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er operate the vehicle on slopes greater than 10 degrees with the plow installed.
NeNe
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er stand or ride on the plow.
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ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
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ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
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ys replace all worn or damaged parts before operating.
NeNe
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er operate this WARN product with damaged or missing parts.
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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.
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ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
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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.
NeNe
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er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
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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.

WARN® INDUSTRIES PAGE 2 80912A0
Before You Begin
This kit is compatible with WARN’s line of ATV winches. Winch sold separately. Please read WARN’s
Winching Technique guide provided with the winch prior to use of this product.
Table of Contents
I. Parts List .......................................................3
II. Tools Required..............................................3
III. Torque Specifications ...................................3
IV. Foreman Installation ................................. 4-5
V. Rubicon Installation ......................................6
VI. Maintenance/Care.........................................6
Caution
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.
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 operating instructions thoroughly.
Notice
Equipment Damage
Always refer to the Installation and Specification Guide, supplied in the winch kit, for all wiring schematics and specific
details on how to wire this WARN product to your vehicle.
Never overtighten the j-bolt to the bracket. Doing so will pinch the winch cable against the bracket, damaging the cable.
Always put the end of the actuator cable through the slot in the Termination Bracket. Terminating the cable through any
other hole in the bracket will cause the bracket to not function properly and will drastically reduce the life of the actuator
cable. Read installation and operating instructions thoroughly.

WARN® INDUSTRIES PAGE 3 80912A0
II. Tools Required
• Ratchet
• Sockets: 1/2”
•Drive extension and u-joint
I. Parts List
Ref Part # Description Qty
A1 79716 Plow Mount Weldment 1
B1 60870 U-bolt, 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

WARN® INDUSTRIES PAGE 4 80912A0
IV. Foreman Installation
1. Figure 1 shows pocket behind front plastic fascia
where front plow mount will be installed. The
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

WARN® INDUSTRIES PAGE 5 80912A0
Figure 4
Figure 5
4. On front side of plow mount place 5/16” washer
and nuts on u-bolts and tighten to 17lb. ft. (22.5
N-m), as shown in Figure 4. An extension and
u-joint attachment on the 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 Installation continued

WARN® INDUSTRIES PAGE 6 80912A0
V. Rubicon Installation
The front plow mount installation is now
complete. Proceed to section VII, entitled
“Maintenance/Care”.
The previous instructions have shown how to mount the front plow mount assembly to the Honda
Foreman, either with or without winch mount installed. The early Rubicon model years have a very
similar mount, however the entire bumper assembly may need to be removed from vehicle allowing
access to install the plow mount assembly with the winch mount.
VI. Maintenance / Care
•Inspect all metal parts on the plow, plow mount, and related hardware. Replace all parts that appears
rusted or deformed prior to use.
•Inspect all nuts and bolts on the plow, plow mount, and related 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 PRIOR TO OPERATION OF ATV AND
WINCH.
WARNING
WARNING
PERFORM REGULAR INSPECTIONS ON THE PLOW, PLOW MOUNT, AND RELATED HARDWARE.
NEVER OPERATE THE PLOW WITH DAMAGED OR MISSING PARTS. FAILURE TO FOLLOW
THIS WARNING MAY CAUSE VEHICLE DAMAGE AND OPERATOR INJURY OR DEATH.
FAILURE TO SECURELY TIGHTEN ALL BOLTS ON
THE PLOW MOUNT, WINCH PLATE, WINCH, AND
FAIRLEAD CAN RESULT IN PRODUCT FAILURE
WHICH MAY RESULT IN VEHICLE DAMAGE AND
OPERATOR INJURY OR DEATH. DOUBLE CHECK
THAT ALL BOLTS ARE SECURELY TIGHTENED
PRIOR TO USE.
WARNING