Installation Guide for YAMAHA models including: 101920 Kodiak Winch Mount KFI, 101920, Kodiak Winch Mount KFI, Winch Mount KFI, Mount KFI
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101920 Yamaha Kodiak 450 Winch Mount - KFI ATV Winch, Mounts and Accessories
YAMAHA KODIAK Winch Mount PART # 101920 Hardware Kit: HK-340 Kit Components: Item 1 2 3 4 5 6 7 8 Qty. 1 1 2 2 2 4 2 2 Description Winch Mount Winch Spacer Plate M6-1.00 X 30MM HEX BOLT GR8.8 ZINC M6 FLATWASHER ZINC M6 HEX NUT NYLOCK GR8.8 ZINC M8-1.25 x 30MM HEX BOLT GR8.8 ZINC M8-1.25 HEX NUT NYLOCK GR8.8 ZINC 1/4" USS WASHER ZINC INSTALLATION INSTRUCTIONS: 1. Remove four bolts (A) from front skid-plate. Retain bolts for re-use (Shown in figure 2). 2. Remove plastic rivets (C) from headlight bezel. Retain for re-use (Shown in figure 3 & 4). 3. Remove top two bolts (B) from the front rack. (Shown in figure 3). C 3 87 2 1 4 5 "Figure 1" Exploded View A "Figure 2" "Figure 4" B C "Figure 3" 1 INSTALLATION INSTRUCTIONS: 4. Remove two bolts (D & E)from each side of the bumper. Remove the bumper from the machine after removal of these bolts. Retain bolts for re-use (Shown in figure 5). Front bumper D 7. The winch power leads on some winches may need to be rotated to prevent contact with the bumper frame (Shown in figure 8). See last page for lead rotation instructions. 8. Place winch onto mount and tighten in place with hardware supplied with your winch (Shown in figure 8 and 9). E FRONT "Figure 5" 5. Attach fairlead to winch mount with hardware provided with your winch (Shown in figure 6). WINCH LEADS "Figure 8" "Figure 6" Note: Some winches may require additional space between the mount (1) and bumper. Place the winch spacer plate (2) between the mount and winch if needed. M8x30mm bolts (6) supplied if spacer plate is used. 6. Place winch mount (1) onto the bumper. Place the spacer (2) on top of mount if your winch requires the additional space to clear the bumper tubing on the bottom side (Shown in figure 7). "Figure 9" Note: if mounting a two hole winch you will use the centered holes on the winch mount and Kodiak bumper. Place M8 bolts from the top through the winch, winch mount, and bumper. Place a 1/4" USS washer (8) onto each bolt and fasten with M8-1.25 hex nuts (7). TWO HOLE WINCH MOUNTING HOLES "Figure 7" 9. Install your contactor on the mount behind the winch with the four included M6-1.00 x 30MM hex bolts (3), M6 washers (4) and M6 nylock nuts (5),(Shown in figure 10). ©2018 Copyright Kappers Fabricating, Inc. All rights reserved 2 D "Figure 10" 10. Verify all winch, contactor, and fairlead hardware E has been tightened. Place the bumper assembly back up to your machine frame. Reinstall the lower two factory M8 hex bolts (E) removed in step 4. Do not tighten yet (Shown in figure 11). 11. Rotate the bumper assembly down to access the contactor. Locate the factory pre-ran Red/Black power and ground wires attached to the radiator hose along the frame under the drivers side front fender (Shown in figure 12). Connect the wires to the corresponding red/black contactor posts (Shown in figure 16). Connect the shorter red/black wires provided with your winch to the contactor. The black wire will go from the blue post on the contactor to the blue post on the winch and the red wire from the yellow post on the contactor to the yellow post on the winch. (Shown in figure 16) "Figure 11" Front 12. Install the Rocker switch to the handle bar and route wires down to the contactor along existing wire bundles. Connect the green and black wires to the contactor. (Note: make sure all green wires are connected to green and black to black). Connect the red wire to a keyed 12 volt power source from the machine. Slide the plastic headlight off cover by removing the two push pins in location (G) Shown in Figure 13. Once the factory harness is exposed you can tap into the PINK (+) wire for your switches shown in Figures 14 & 15. NOTE: Make sure handlebars can move freely then fasten wires in place. "Figure 12" G "Figure 13" F Pink Wire Positive (+) "Figure 15" "Figure 14" 3 13. Rotate the bumper assembly back up into place and install the upper two M8 hex bolts (D). Tighten all four M8 bolts to secure the bumper assembly (Shown in figure 11). 14. Reinstall bolts into front rack (B), plastic rivets in headlight bezel (C), and four bolts attaching the skid plate. See steps 1-3. (Shown in figure 2, 3 &, 4) 15. Locate the factory installed power and ground wires near the battery. The positive wire is found under the drivers side rear fender zip tied to the frame. The negative wire is already routed into the battery compartment under the seat. Connect wires to the respective positive and negative battery terminals (Shown in figure 14 & 15). NEGATIVE "Figure 18" Factory wires from battery Yellow(+) Blue (-) Red (+) Black (-) "Figure 16" DR. SIDE REAR FENDER POSITIVE REAR "Figure 17" ©2018 Copyright Kappers Fabricating, Inc. All rights reserved 4 WINCH LEAD ROTATION D B CA A "Figure 1" 1. Remove bolts (A) on motor end cap as shown in Figure 1&2. A "Figure 2" 2. Remove motor end cap (B) and rotate 90 degrees. Make sure that the brushes (C) are seated properly be for reinstalling end cap. Note: On some winches you many need to rotate the motor housing (D) as the magnets are not always spaced the same. "Figure 4" 3. Reinstall bolts (A) and tighten down. "Figure 3" Threaded Rotation Holes 5Adobe PDF Library 9.0 Adobe InDesign CS4 (6.0.6)