2000+ Honda Rubicon ATV Plow Mounting Kit Installation Instructions
Installation
1. Slide four 5/16” dia x 1-1/4” wide U-bolts (C1) over the underside frame of the ATV. If unsure of their location, position the plow mount (A1) against the underside of the ATV, just in front of the skid pan, and find the approximate location of where the U-bolts go.
2. Once the U-bolts (C1) are in place, position the plow mount (A1) under the vehicle, and slide the legs of the U-bolts through the eight holes in the plow mount. Work on one U-bolt leg at a time, as a threaded end is exposed, terminate the U-bolt leg with a 5/16” dia flat washer (C2) and 5/16” dia nylock nut (C3). Continue until each U-bolt has a washer and nut on the end of it.
NOTE: Do not tighten the bolt and nut completely. You will do this in the next step
3. Tighten all the 5/16” dia nylock nuts (C3) on the plow mount (A1). Tighten each nut just a little and work around each one until they are tightened to a recommended torque of 12 ft-lb (16 N-m). The completed plow mount should look like figure 1.
4. If not already done so, assemble the plow per the instructions that came with the plow blade kit. Attach the plow to the plow mount (A1) using the clip pins that came with the plow blade. Use figure 2 to determine which mounting location to use. Those using a winch to lift their plow should use the forward holes, while those using an electric actuator should use the rearward holes. If using an electric actuator or manual lift to raise your plow, stop here and proceed to section IV, Maintenance/Care. Winch users continue with step 5.
5. Attach the J-bolt bracket (A2) to the center hole in the plow crossmember using a 3/8” dia x 1” long bolt (D1) as shown in figure 3. The bracket should be mounted on the blade side of the crossmember with the side flanges parallel to the ground. Terminate the bolt with a 3/8” dia flat washer (D2) and 3/8” dia nylock nut (D3). Tighten the bolt and nut to a recommended torque of 20 ft-lb (28 N-m).
6. Run the winch cable over the roller fairlead and down to the J-bolt bracket (A2). Using a 1/4” dia J-bolt (B1), hook the loop on the end of the winch cable and slide the threaded end of the J-bolt through the round holes in the J-bolt bracket. The hook end of the J-bolt should slide into the slotted hole in the J-bolt bracket. Terminate the end of the J-bolt with a 1/4” dia flat washer (B2) and 1/4” dia nylock nut (B3). Tighten the nut until the winch cable is snug inside the J-bolt as shown in figure 4.
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