Warn 87190 User manual

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 1 87197 A1
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
PLOW MOUNT KIT
Part Number: 87190
Application: 2012+ Honda Foreman 500
GENERAL SAFETY PRECAUTIONS
WARNING
IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death
• Always Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.
• 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wearsafetyglasseswheninstallingthiskit.Adrillingoperationwillcauseyingmetalchips.Flyingchipscancauseeyeinjury.
• Alwaysuseextremecautionwhencuttingandtrimmingduringtting.
• Always remove jewelry and wear eye protection.
• Never lean over battery while making connections.
• Never route electrical cables:
o Across any sharp edges.
o Through or near moving parts.
o Near parts that become hot.
• Always insulate and protect all exposed wiring and electrical terminals.
• Always install terminal boots as directed in installation instructions.
• 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 instructions.
• Always operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.
• Always plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.
• Never operate the vehicle on slopes greater than 10 degrees with the plow installed.
• Never stand or ride on the plow.
• Always stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.
• Always perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
• Always replace all worn or damaged parts before operating.
• Never operate this WARN product with damaged or missing parts.
• Always 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.
• Always drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.
• Always 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.
• Never raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.
• Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
Read installation and operating instructions thoroughly.
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.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 2 87197 A1
NOTICE
EQUIPMENT DAMAGE
• AlwaysrefertotheInstallationandSpecicationGuide,suppliedinthewinchkit,forallwiringschematicsandspecic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.
CAUTION
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury
• 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inuenceofdrugs,alcoholormedications.
Read installation and operating instructions thoroughly.
NOTES
BEFORE YOU BEGIN
TABLE OF CONTENTS
Tools Required.......................................................................................................page 2
Torque Specications............................................................................................page 2
Parts List................................................................................................................page 3
Installation......................................................................................................... page 4-8
Tips/Troubleshooting ............................................................................................page 9
Maintenance/Care................................................................................................page 9
• Beforebeginningplowmountinstallation,allowtheengineandexhaustsystemtocoolanddisconnectthenegativecable
fromthebattery.
Note: If a Warn winch mount is installed it does not need to be removed
to install this plow mount.
Note: Loosening the factory front tube guard bolts may aid in installation of this kit. Be sure to
Re-tighten factory bolts when installation is complete.
TOOLS REQUIRED
• Ratchet and Torque wrench
• Sockets: 10mm, 12mm, 13mm, 17mm
• Wrenches: 10mm, 12mm, 13mm, 17mm
• 5mm Hex Wrench
• Screwdrivers: Slotted, Phillips
• Sidecutters, Saw or Utility knife
TORQUE SPECIFICATIONS
6mm - 13 N-m (10 ft-lb)
8mm bolts - 16 N-m (12 ft-lb)
8mm U-bolts - 13 N-m (10 ft-lb)
10mm bolts - 47 N-m (35 ft-lb)

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 3 87197 A1
PARTS LIST
ITEM QTY NAME
1 1 PLATE
2 1 BRACKET
3 1 PLOW MOUNT BRACKET
4 4 6 MM SOCKET HEAD BOLT
5 6 10 MM CARRIAGE BOLT
6 2 8 MM U-BOLT
7 1 LEFT MOUNT TAB
8 1 RIGHT MOUNT TAB
9 6 10MM NUT
10 2 8 MM BOLT
11 2 PIN
12 4 8 MM NUT
13 2 SPACER
14 4 8 MM WASHER
15 4 6 MM NUT
NOT REQUIRED WHEN INSTALLED WITH WARN
WINCH MOUNT
A
A
NOTE: WHEN CONNECTING PLOW TO MOUNT BRACKET, THE PIN RETAINING WIRE
INSTALLS THROUGH THE BACK OF THE PLOW MOUNT BRACKET
PLOW PUSH TUBE ATTACHMENT HOLES

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 4 87197 A1
INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS
1. Remove front 6mm bolts and clip pins from plastic guards.
2. Partially remove bottom plastic guard and remove two lower
factory front tube bolts.
3. Remove A-arm plastic guard.
c = clip pin, b=6mm bolt
b
bc
b
b
c

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 5 87197 A1
4. Install plate over front differential and behind frame tubes.
Fasten using 8mm U-bolt. Do not tighten.
5. Install bracket in front of frame tubes. Fasten to plate using
10 mm carriage bolts and nuts. Do not tighten.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 6 87197 A1
6. Install plow mount bracket under frame. Fasten to frame
and plate using 8mm bolts and 10mm carriage bolts and
nuts. Do not tighten.
Note: If installing with the Warn winch mount, remove and
discard the u-bolts that attach the winch mount to the
frame.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 7 87197 A1
1
3
2
4
7. When a winch mount is not installed, the plow mount
bracket will need to be fastened to the frame using a
spacer and washer.
8. Tighten bolts to recommended torque specications listed
on page 4 and in the order shown.
9. Install 6mm socket head bolts and nuts.
10. Lift lower plastic guard up against the lower plow mount
bracket and mark plastic for trimming. Trim plastic as
required for clearance. Re-attach lower plastic guards
using bolts and clips removed in step 1-3.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 8 87197 A1
11. Install mount tabs onto inside of push tube assembly
anges. Pucks need to be facing inward and away from
plow blade. Fasteners are included in the push tube kit.
12. Reconnect battery ground.
Operation:
1. Stage the plow assembly on level solid ground. See Plow
operator guide “Installing the Plow” for more information.
2. SLOWLY drive the vehicle up to the plow assembly with the
vehicle as square to the plow as possible.
3. Turn off the vehicle and set the parking brake. Lift the plow
mount ange end of the push tube assembly up to the plow
mount on the vehicle. Insert the plow mount ange into the
plow mount.
4. Double check that the plow is fully engaged with the plow
mount, resting on the two lower ¼” socket bolt heads.
5. With both alignment pucks seated into the plow mount the
retaining pins can be inserted. Once inserted the retaining
clips on the pins can be clipped through the hole in the
back of the plow mount bracket. See Plow operator guide
“Installing the Plow” for more Information. The parts list
view shown at the beginning of this document shows the
pin location details for this application.
6. Attach the winch line to the push tube assembly through
the rope guide as described in the Plow operators guide, or
attach the electric plow lift.
7. Turn the ignition switch to ON, and operate the winch
or electric lift to lift and lower the plow. The plow is now
ready for operation. Read the Plow Operators Guide before
operating plow.

©2011 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. 9 87197 A1
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.
TROUBLE SHOOTING
MAINTENANCE / CARE
• Avoidengagingorremovingtheplowfromthevehicleonuneven,sloped,orsoftground.Doingsomaymisaligntheplow
mountandmakeitdifcultforproperengagementanddisengagementoftheretainingpins.
• Ifyouarehavingtroublegettinganalignmentpuckintotheplowmount,itmayneedsomesimpleadjustment.Ensurethat
theplowandvehiclearesittinglevel.Ensurethattheplowbaseisinthecenterlatchedposition.
• Afterusingtheplow,thewinchcablemaybegintotanglearoundthedrum.Toxthis,pullofftheplowassemblyandfree
spoolthecableoutofthewinch.Oncethetangledcableispulledoffthedrum,switchthewinchoutoffreespooland
winchthecableneatlybackaroundthedrum.DoNOTgrabthecableorwinchhook,insteadusethewinchhookstrap
providedwithyourwinchandfollowtheguidelinesasdescribedinthewinchingguide.
• Inspectallmetalpartsontheplow,plowmount,andrelatedhardwarepriortoeachuse.Replaceallpartsthatappear
rustedordeformed.
• 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mustbereplaced.
• 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.
• SeeWarnPlowOperatorsGuideformoreinformation.
If you are having problems with your plow, please follow the steps below:
1. Reference the installation instructions for tips or notes.
2. Contact the dealer where you purchased the kit.
3. Call an authorized WARN Service Center from the warranty sheet included in the kit. Please have the following information
available before calling; part number (listed on front of instructions), date of purchase, and make, model, and model year of ATV.
4. Contact WARN customer service at 1-800-543-9276 or www.warn.com. Again, please have the following information available
before calling; part number (listed on front of instructions), date of purchase, and make, model, and model year of ATV.
WARNING
Failure to perform regular inspections and maintenance on the plow, plow mount, winch, and related hardware may
result in vehicle damage and operator injury or death.
Thefollowingreplacementpartsareavailableforpurchase:
Part # Description Notes
 71493 QuickReleasePinkit  2x35136
