Honda, Polaris (2000 and older) ATV Thumb Warmer Installation Instructions

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Filed Under (Honda) by admin on 15-12-2011

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Hi/Low Switch Installation Choose a location for the switch, which is convenient and has sufficient rear clearance for the electrical connections and is within 18″ of a voltage-controlled wire (a wire in the lighting circuit). Drill a 1/2″ (13mm) hole and install the switch from the back. Leave the strain relief nut on the switch. On the front install the Hi/Low indicator tab and secure the switch and tab using the metal nut. The amount of switch barrel protruding can be adjusted by moving the strain relief nut. Wire Routing and Connections Route the electric cord along the handlebar to switchmarea and secure with supplied tie wraps, electrical tape, or both. Cut and strip to proper length. Attach a ground wire of sufficient length to go from the red wire to a good ground. WARNING: Lead wire slack in the area of the throttle must be neither excessive nor tight. Ensure no binding occurs when the throttle is open fully.,Soldering connections is the most durable method, but the following will provide years of service. Attach the 1/4″ female slip-on connectors to the white and blue wires and #10 ring terminal to warmer leads as shown in Figure 2. (A crimping tool works best, but a Vise Grips or pliers will work). Figure 2. Switch Connections (Option B) Connect the single yellow or red wire to a regulated (lighting) circuit using Option A (ATV has a switch in a lighting circuit with a 1/4″ tab) or Option B: Option B: Locate a power wire (usually yellow) leading to a headlight, taillight, or dash light (Figure 2). Using the red tap connector, place this power wire into the continuous channel and insert the red wire (do not strip insulation) completely to stop in the second channel. Make the connection by squeezing (w/pliers) the metal contact until flush with the top of the connector. Close the hinged cover until latched. Complete connections to switch and ground circuit.

Honda Foreman 500 And Honda Rubicon WINCH MOUNTING KIT INSTALLATION

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Filed Under (Honda) by admin on 13-12-2011

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Begin by removing the front skid plate located on the front of the ATV. Remove the four side 8mm bolts and four bottom 6mm bolts securing the front skid plate, figure 1. Save the fasteners as they will be used later to reinstall the front skid plate. 2. Remove the four plastic rivets on each side of the front plastic fascia, figure 2. Use a large screw driver to carefully remove the center rivet. After removing the center rivet, remove the rivet housing. Save the fasteners as they will be used to reinstall the front plastic fascia. 3. Remove the two 6mm bolts that attach the front plastic fascia to the bumper, figure 3. Remove the front plastic fascia at this time . Remove the two 6mm bolts that attach the front bumper to the plastic headlight assembly, figure 4. Save the fasteners as they will be used to reinstall the front bumper. 5. Remove the two top 8mm bumper bolts that attach the front bumper to the front rack, figure 5. Save the fasteners as they will be used to reinstall the front bumper. Figure 5 Remove Top Bumper Bolts Remove (both sides) 6. Remove the two ottom bumper bolts that attach the bumper to the bottom of the vehicle frame, figure 6. Save the fasteners as they will be used to reinstall the front bumper

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Express ATVS -250cc Cobra Setup/ Installation Manual

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Filed Under (Cobra) by admin on 10-11-2010

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Unpacking your Cobra Installing the front shock Installing the front tires Installing rear shocks Installing the rear tires Installing seats and harnesses Steering wheel installation Roll cage installation Safety checks / Adjustments General maintenance Unpacking your Cobra First off you should pull the carton off from your new 250 Cobra cart. Inspect the cart thoroughly to make sure that your new Cobra has not been heavily damaged. You will notice that the product has a metal frame holding it in place; you may want to start removing bolts from the shipping steel frame. The next step is to remove the metal frame and lift it off of the cart. Remove any of the metal frame that may afford resistance when working on the cart it self. Be careful the metal frame may be heavy and sharp. Now would also be a good time to inspect your Cobra a little more thoroughly. In the box with the Cobra you should have found a box containing miscellaneous hardware. Installing the front shock Using some of the bolts you found in your box, install the front shocks sliding the bolt through the brackets and tighten the nut down. Next, you will need to place the ball head into the turning arm, then tighten the castle nut and insert a cotter pin so that the castle nut doesn’t loosen and become a hazard. Installing the front tires
Find the front tires and place them on the front hub and place the lug nuts on the studs. Tighten them down. Make sure that all of the lug nuts are on tightly. Installing the rear shocks Moving to the rear of the Cobra you will notice the rear shocks are not inserted. Place the rear shocks into the bracket on the rear of the Cobra. Slide one of the provided bolts through the bracket and shock eyelet and tighten the bolt down. Installing the rear tires Now that the shocks have been placed properly you can install the rear tires, place the tires onto the axle then place the rear rim lined up onto the axle and tighten the provided castle nut down. Place the cotter pin through the axle and bend off to the side. This is so the castle nut does not loosen under load. Installing the seats and harnesses
(The arrow points to an example of where the seat bolts mount) Find the two racing seats shipped in the box with the Cobra. You will need to affix them to the frame by sliding the bolts up through the bottom of the frame. This can be tricky so have patience. Once both seats have been placed in the cart and tightened find the harnesses. Once found the harnesses mount to a bracket behind the seats. Place a bolt through the bracket and bolt the harnesses down tightly. Installing the steering wheel Find the steering wheel and place it onto the steering wheel mount. Grab the six small screws and place them through the steering wheel and mount, tighten them down but also make sure the top of the wheel is facing up. Installing the roll cage

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KYMCO MXU 375 ATV WINCH MOUNT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kymco) by admin on 26-10-2010

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WINCH MOUNT INSTALLATION INSTRUCTIONS 1. Remove molded plastic bumper guard from the ATV. 2. Mount the winch mount weldment (Item 1) to the ATV as shown below. 3. Mount the roller hawse to the winch mount weldment as shown above. 4
4. Mount the winch to the winch mount weldment and route the winch cable through the rollers. (Installer may need to remove rollers to allow cable end to pass through). 5. Wire the winch according to the manufacturer instructions. 6. Re-install the molded plastic bumper guard. 5 *CAUTION BE AWARE OF WHEN THE CABLE STOP CONTACTS THE ROLLER HAWSE AS CABLE IS WOUND IN. FAILURE TO RELEASE MAY CAUSE DAMAGE TO WINCH PARTS OR TO THE ATV. When using the winch to raise and lower a blade a cable stop must be installed. Carefully raise the blade until the top of the push tube’s are no closer than 1″ anywhere on the ATV. Place the Cable Stop onto the Winch Cable up against the Winch Hawse. Secure the Cable Stop to the Winch Cable using the Cable Clamp Assembly as shown in the pictures below.

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Kawasaki Winch Mount Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. You will need to remove the lower Front Moulding of the ATV for installation of the Winch Kit. 2. Position the Winch with the motor on the LEFT side in the mounting location and slide the Winch Mount Plate in under the winch. Attach the Winch Mount Plate to the frame with the U-bolts and Nylock Nuts provided. Tighten at this time. See Picture Winch Mount Plate 3. Install the Roller Hawse Bracket to the Lower Winch Plate and to the front bars (behind the bars) of the ATV using the U-bolts, Carriage Bolts and Nylock Nuts. See Picture Below. Winch Mount Plate Roller Hawse Bracket 4 4. After winch installation is complete, reinstall lower Front Moulding of ATV. Remove one of the long rollers and the two side rollers and feed the winch cable through the roller hawse. Reinstall the rollers and be sure rollers move freely. Attach the Roller Hawse to the Roller Hawse Mount Plate using the 3/8″ x 1″ Bolts and Nylock Nuts provided with the winch. Tighten all hardware

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