installation instructions 424 select - …warn.iwebcat.com/imgvd/war/63748a1-pn62616.pdf ·...

WARN INDUSTRIES PAGE 1 63748 A1

INSTALLATION INSTRUCTIONS424 SELECT

WARNINGA change in the handling characteristics of your ATV will occur in the 4X2 mode.

Honda Model Year Warn PN300.................................................................1988-1992.................................................. 64626300.................................................................1993-2000.................................................. 62624400.................................................................1995-1997.................................................. 62623400.................................................................1998-2001.................................................. 63744400.................................................................2002-2003.................................................. 66057450.................................................................1998-2002.................................................. 63560Rancher...........................................................2000-2003..................................................63559Rubicon...........................................................2000-2003..................................................62616

NOTICEDo not switch to engage 4X4 if the rear tires are spinning. This may cause severedamage to the 424 Select unit.

CAUTIONRead and understand all instructions before procedding. Make sure that you have allnecessary tools and parts before beginning the installation. Refer to the owner’s manualfor detail illustrations on your particular Yamaha model.

Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have providedinstallation and operating instructions and other information on labels and in this guide. This information alerts you to potentialhazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, youmust use your own good judgment.CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ ANDUNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THISPRODUCT.This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury ordeath. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean:

signals a hazard that could cause serious injury or death, if you do not follow recommendations. signals a hazard that may cause minor to moderate injury, if you do not follow recommendations.

This guide uses to call attention to important mechanical information, and Note: to emphasize general information worthy of specialCAUTION

WARNING

NOTICE


FENDER AND SKID PLATE REMOVAL

1. Block rear tires and raise front of vehicle.2. Remove left front tire.3. Remove the four fasteners attaching the skid plate

to the front of vehicle (Fig. 1)

Note: The Honda Rancher, 400, and 450 all havealuminum front skid plates. The Rubicon has aplastic skid plate and the Honda 300 does nothave one.

4. Remove the front fender/guard mud flap on the left side of the vehicle. Pull up the clip center usingsnap ring pliers, flat head screwdriver, wire cutters (Do not cut off clips), or equivalent, (Fig. 2).Remove necessary stay screws and clips (Fig. 3).

5. Remove the left inner fender (Fig. 4).


FRONT PROPELLER SHAFT REMOVAL

Note: If installing a 424 Select unit on a Honda 300, it is ncessary to drain the frontdrive case and front differential.

1. Remove front propeller shaft guard by removing the retaining clips and bolts holding guard inplace, (Fig. 5 and Fig. 6).

2. Loosen the front differential by removing the following:• Two front differential mouting bracket bolts (Fig. 7).• The upper mounting bolt, nut, and spacer (Fig. 7).• Rear mounting bolt (Fig. 8).


3. Remove the shaft seals and o-rings from the engine drive sleeve and front differential (Fig. 9). Pushthe front differential forward as far as possible (Fig. 10).

Note: There is not an engine drive sleeve on the Honda 300 model. Also, not every Hondamodel will have shaft seals and o-rings on the front propeller shaft.

4. Pull the drive sleeve forward compessing the spring. Separate the propeller shaft from the engine (Fig.11). Remove the drive sleeve and spring for reinstallation with the new 424 Select unit.

5. Remove the propeller shaft from the front differential by pulling it out while holding the front differentialforward.

6. Remove the retaining ring from the original front pro-peller shaft. Save retaining ring for reinstallation with thenew 424 Select unit.

Note: The Honda 300 will not have this retain-ing clip.


424 SELECT INSTALLATION

1. Apply molybdenum disulfide grease to the splines and dust seals of both ends of the new 424 Select unit(Fig. 14).

2. Install retaining ring, (Fig. 15), on the front differential end of the 424 Select unit (the side the cable isprotruding from).

3. Install drive sleeve and spring from the old frontpropeller shaft and install onto the new shaft endopposite of the cable (Fig. 16).

As noted earlier, the Honda 300 will not havethis drive sleeve.

4. From left side, route control cable forward throughchassis ahead of 424 Select unit (at this point, therouting of the control cable is to keep it out of theway while installing 424 Select unit into position)

CAUTIONAvoid kinking or damaging the control cable and

housing during installation.


5. Position the 424 Select unit behind the front differ-ential (cable towards the front differential). Install theoutput propeller shaft into the pinion joint at the frontdifferential. Compress the drive sleeve and springonto the 424 Select unit and connect to the engineoutput shaft. Rotate the shaft slightly if necessary toalign the spline.

Torque SpecificationsMounting Bracket Bolts: 22 N.m (2.2 kg-m, 16lb-ft)Differential mounting bolts: 45 N.m (4.5 kg-m,33 lb-ft)

6. Reinstall the front differential by installing the following:• Two front differential mounting bracket bolts (Fig. 7).• The upper mouting bolt, nut, and spacer (Fig. 7).• Rear mounting bolt (Fig. 8).

7. Fit dust boots into location and place o-ring intogroove in boot (Fig. 19).

8. Using the 5/64” allen wrench, attach the anti-rotation bracket to the 424 Select using the 8-32 screwand lockwasher (Fig. 20). Do not tighten at this point. Attach the anti-rotation strap to this bracketusing the 1/4-20 bolt, fender washer and lock nut. Attach anti-rotation strap to frame using 1/4” - 20u-bolt, washer and lock nut provided in kit (Fig. 21).

Note: Strap location will vary depending on vehicle.

CAUTIONAvoid damaging the new dust seals and boots when

installing the 424 Select unit.


9. At this point the anti-rotation bracket and all other mounting hardware can be tightened.

CONTROL CABLE ROUTING

1. To route and install cable it is necessary toremove handle assembly from the cable. Re-move black handle by loosening setscrew, andunscrewing handle from brass sleeve, Figure22.

2. Unscrew mounting sleeve from cable adjuster(two silver knurled pieces), Figure 23.

3. Push button and brass piece through mountingsleeve just enough so cable can be removed,Figure 24.

4. Remove 9/16" nut from cable adjuster for easierrouting. Route cable using the least number ofand largest bends possible to allow for thesmoothest operation of cable. The initial routingshould be above the differential and below thesteering control arms.

CAUTIONAvoid kinking or damading the control cable

and housing during installation.

Mounting Sleeve

Cable Adjuster

9/16” Nut

Handle

Ball & ShankEnd Crimp

Brass

CAUTIONThe424 Select unit should be allowed to rotate slightly.

Do not stretch or over tighten strap.

Fig. 22

Fig. 23 Fig. 24


5. Recommended locations for control cable mouting bracket:

6. Route cable using the least number of and largest bends possible to allow for the smoothest operation ofcable. The initial routing should be above the differential and below the steering control arms (Fig. 25and Fig. 26).

Model Bracket Location Cable Routing Through PlasticRubicon ..................... Right side vehicle .................... Through right side rack mounting hole

450 ......................... Right or left side ................ Through rack mounting hole or drill 5/8" hole400 ......................... Right or left side ................ Through rack mounting hole or drill 5/8" hole

Rancher ...................... Right or left side ................ Through rack mounting hole or drill 5/8" hole300 ......................... Right or left side ....................................... Drill 5/8" hole


7. Remove front rack if routing cable through rack-mounting hole in plastic (Fig.29). Figure 29 shows thecable going through the rack-mounting hole.

Note: If drilling a 5/8” hole for the cable routing, the location should be towards thefront of the ATV to minimize sharp bends in the cable.

8. If necessary, use cable ties to keep cable away from moving parts (Fig. 25). If used, keep ties loose toall free operation of cable.

Note: Route cable under rack to avoiddamaging cable if rack is loaded(Fig.30).

9. Determine mounting location for bracket. The locationwill vary from vehicle to vehicle, refer to table on page8 for the recommeded location. Figure 31 shows themouting location for the Honda 450. For best results,assemble cable and handle assembly in mountingbracket and hold it in different desired locations.

Note: Before drilling, verify the handle is clear of any obstruction while turning thehandlebars. Turn handlebars to full left and right.

10. Using mouting bracket as a template, mark and drill two 1/4” holes through plastic (Fig. 32 & Fig. 33).

WARNINGKnow what is behind plastic when drilling.Avoid all electrical wires and DO NOT drill

into the gas tank.


11. Mount bracket using two ¼" – 20 x 1" bolts, lock nuts and fender washers. Slide mounting sleevethrough mounting bracket and hand tighten 3/4" nut.

12. Before reinstalling handle assembly make sure 9/16" nut is threaded on cable adjuster. Install cable byputting ball & shank end crimp in brass slot, and push brass back through mounting sleeve Figure 24.

13. Thread cable adjuster and mounting sleeve together, Figure 23. Make sure brass piece is far enoughin mounting sleeve to engage threads.

14. Install black handle until threads bottom out with light finger pressure, Figure 22. Do not over tighten. Tighten set screw.

Note: Do not use pliers on brass

CABLE ADJUSTMENT

Test for proper operation of the 424 Select unit.The cable should have a smooth pull and shouldpositively lock into the 4X2 mode when pulled.Release the cable and shift into 4X4 by depressingthe push button. If cable assembly feels stiff or willnot lock into position, adjust cable assembly in atthe adjuster (less thread showing) until proper feel isachieved, Figure 36. The handle should bottomout on the mounting sleeve in 4X4, (no brassshowing). After properly adjusting, tight 3/4" and 9/16" nut.

Push Button Fig. 36

Cable Adjuster

SERVICE KIT PART NUMBERS

Warn PN 63739 Cable Replacement KitWarn PN 63743 Bearing/Seal Replacement Kit

installation instructions 424 select - …warn.iwebcat.com/imgvd/war/63748a1-pn62616.pdf ·...

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