Warn 79673 User manual

WARN® INDUSTRIES PAGE 1 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
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: 79673
Applications: 2006-2009 Honda Rincon 680
2003-2005 Honda Rincon 650
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.
AlwAlw
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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
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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.
AlwAlw
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ys use appropriate and adequate care in lifting components into place.
AlwAlw
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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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verer
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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.
AlwAlw
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ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.
AlwAlw
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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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vv
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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.
*Not compatible with 2.5ci and A2000 winches.

WARN® INDUSTRIES PAGE 2 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Table of Contents
I. Parts List .......................................................3
II. Tools Required..............................................3
III. Torque Specifications ...................................4
IV. Rincon Installation .................................... 3-7
V. Rubicon Installation ......................................8
VI. Maintenance/Care.........................................8
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.
This kit design is compatible with RT/XT WARN winches. Other winches may not fit. Contact customer service with
questions on application.Read installation and operating instructions thoroughly.
Before You Begin
This kit is compatible with WARN’s RT/XT line of ATV winches. Other winches may not fit.
Winch is sold separately. Please read WARN’s Winching Technique guide provided with the winch prior to
use of this product.

WARN® INDUSTRIES PAGE 3 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
II. Tools Required
• Ratchet
• Sockets: 10mm, 12mm, 13mm, 7/16”, 1/2”
• Wrenches: 13mm, 7/16”
•Allen Wrenches: 5mm
•Drive extension and u-joint
•Needle Nose Pliers
•Shears or a similar cutting device
I. Parts List
Ref Part # Description Qty
A1 79670 Plow Mount Weldment 1
A2 80685 Bottom Mount Bracket 1
B1 60869 U-bolt, 5/16-18x1-3/8x2.0 2
B2 1324 5/16” flat washer 4
B3 2002 5/16-18 lock nut 4
C1 7146 Capscrew, 1/4-20x.75 2
C2 6725 1/4-20 lock nut 6
C3 21444 U-bolt, 1/4-20x3/4x1-1/4 2
D1 79712 3/8” Safety Retaining Clip 2
B3
C2
D1
C1
A1
B1
B2
C2
C3
D1
C1
A1
B2
B1
C2
B3 B3
C2
D1
A2

WARN® INDUSTRIES PAGE 4 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
IV. Rincon Installation (with winch
mount installed)
1. Remove the front aluminum skid plate on the
vehicle, as show in Figure 1. Save the fasteners
as they will be used later to reattach the skid
plate.
2. Disconnect both cables from winch. Remove
hardware to free winch from bottom bracket, as
shown in Figure 2. Remove capscrews, which
connect top bracket to bottom bracket and the u-
bolts at bottom, which connect bracket to vehicle
frame. Keep the top mounting hardware and
discard the lower hardware as longer u-bolts will
be required. Remove winch and bottom bracket
from vehicle.
3. Place winch inside plow mount, as shown in
Figure 3 and carefully slide into vehicle frame
from the side.
Figure 1
Remove
fasteners
Figure 3
Figure 2
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)
Remove hardware to free bottom
bracket and winch

WARN® INDUSTRIES PAGE 5 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Install
Hardware
Figure 4
Figure 5
Figure 6
Ensure mount level
with frame
4. Once winch and plow mount are inside vehicle
frame, as shown in Figure 4, reinstall winch
mounting hardware (8mm capscrews) and torque
to 17 lb. ft. (22.5N-m). Next reinstall top 8mm
capscrews (2) that connect top bracket to bottom
bracket using the original hardware. Do not
tighten at this time. Finally, install 1/4-20
capscrews (2) that connect plow mount assembly
to the bottom bracket. Do not torque at this time.
5. Install the 5/16-18 u-bolts around the vehicle
frame through the back side of the plow mount
assembly, as shown in Figure 5. As a result of
limited clearance, needle nose pliers can be
used to place the washers over u-bolts and 1/2”
socket with an extension and u-joint will make it
easier to install the nuts on the u-bolts. Do not
tighten in place at this time. The access slot on
front side of bottom bracket may be used to allow
tool access to help tighten the nuts of the u-bolts
in place.
6. As viewed from the front of vehicle, see Figure 6,
make sure plow mount is level with vehicle
frame. Once in place, tighten all hardware and
torque to specifications. Winch cables can now
be reconnected.
IV. Rincon Installation continued

WARN® INDUSTRIES PAGE 6 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 7
Figure 8
Trim skid plate as required
Figure 9b
7. Once mounts are secured in place, replace front
aluminum skid plate on vehicle, as shown in
Figure 7. Some trimming may be required in the
area of the plow mount to allow skid plate to bolt
up to original mounting location.
8. See Figure 8 for completed installation. Fairlead
can now be reattached to the mounting plate.
V. Rincon Installation (without winch
mount installed)
1. Remove the front aluminum skid plate on the
vehicle, as shown in Figure 1 of previous section.
Save the fasteners as they will be used later to
reattach the skid plate. Figure 9b shows the
vehicle frame where the plow mount assembly
will be mounted.
IV. Rincon Installation continued
Figure 9
Install the plow mounting tabs.
1. The plow mounting tabs supplied in this kit must
be secure to the plow in the position shown.
(Figure 9).
2. Loosely install the M10 bolts from the plow kit.
Attach the plow to the plow mount and then
secure the plow mounting tabs. This will insure
the best fit for your vehicle.

WARN® INDUSTRIES PAGE 7 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
Figure 10
1/4-20 capscrew and locknut
Figure 11
2. Install the lower plow mount support bracket on
crosstube of vehicle frame, as shown in Figure
10. Use the 1/4-20 u-bolts and 1/4-20 locknuts
to secure in place, but do not tighten at this time.
Lay the plow mount assembly on top of the
bracket and lean against the rear frame to get
the correct orientation. Remove plow mount
assembly and torque u-bolt mounting hardware
to 8lb. ft. (10.8 N-m).
3. Place plow mount assembly on top of lower
mounting bracket. Line up holes and use 1/4-20
capscrews to secure in place as shown in Figure
11. Torque 1/4-20 nuts to 8lb. ft. (10.8 N-m).
4. Install 5/16-18 u-bolts around vehicle frame and
through back side of plow mount assembly as
shown in Figure 12. Torque hardware to 17lb. ft.
(22.5 N-m). Once mount is secured in place,
replace the front aluminum skid plate on vehicle,
shown in Figure 7 of previous section. Some
trimming may be required in the area of the plow
mount allowing skid plate to bolt up to original
mounting location. See Figure 8 of previous
section for completed installation.
Figure 12
Lower mounting bracket
5/16-18 u-bolts
V. Rincon Installation continued

WARN® INDUSTRIES PAGE 8 79671A2
©2011 Warn Industries, Inc.
WARN® and the WARN logo are trademarks of Warn Industries Inc.
VI. 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 Rincon,
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.
VII. 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