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Installing a winch

14K views 51 replies 27 participants last post by  Laundryboy  
#1 ·
I have been working all arvo on fitting this dam winch and still not finished! Anyone else find fitting a winch an absolute pig of a job?! Instructions were very poor and only got as far as I did thanks to Super atv's YouTube video on winch instal.
 
#4 ·
I got an EMP winch mount with a 4000lb Warn winch. I had dramas gettin the bolts on the winch plate connecting to the frame. Tight spaces and it just seemed like they weren't meant to be. Felt like just welding it on!
Any way it's on now and all wired up and works. Look forward to a test run with it
 
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#5 · (Edited)
I guess I could kind of see that..the EMP mount isn't perfect IMO, I had no trouble with the install but i do seem to recall it didnt sit flat on the frame brace it bolts to at the front, the angle is off IIRC..when I tightened the bolts it had to bend that brace a little to sandwich the mount and the brace together. The EMP was all that was readily available when I did mine..if I was to buy a mount now I think I'd try the KFI.

Edit..just looked at mine to refresh my memory..it was the rear that the angle was off and didn't sit flat on the frame.
 
#8 ·
HAHA, I use to have a 6.0L that I built a drag truck out of. The thing was bad ass, but to do anything on that engine you had to pull the body.

But yes the winch install can be a little pain in the ass
 
#15 ·
I installed the EMP mount and Warn XT30 and it fit perfect. Granted it was a very tight fit and frustrating reaching into confined areas. It would have been a lot easier if I had a set of gear drive wrenches.
 
#10 ·
i did mine today ! take about 3 hours for final installation and work great. but yes, the instalation was a pain. really tight and i had to drill the mounting plate because they drill 2 holes smaller than suppose. after that no problem for the rest. mine is viper elite 5000lbs with flush dash switch and remote from moto alliance.
 
#18 ·
The contactor studs are color coded so matching the wires up there shouldn't be too had for you. I mounted the contactor on the firewall behind the coolant overflow bottle. I drilled two 3/4" holes on the fire wall above where the center console meets the firewall. One for the power and ground to the battery and the other for the winch control harness that I mounted next to the 12v socket.

I drilled holes along the driveshaft tunnel and zip tied the power wires up along the left side. The harness for the 12v accy plug has the orange and white wire with the female bullet plug for your winch control.

On the winch housing, the yellow wire will go to the front post and blue to the rear. Once wired, check the polarity using the winch switch. Free spool some cable out and use the pendant to roll cable in. If it rolls out, reverse the polarity at the winch by swapping the blue and yellow wires

Typed on my iPad, so forgive me for any spelling mistakes
 
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#20 ·
There should be holes already in the firewall near the glove box for mounting the contractor. I highly suggest mourning it on the inside if the Polaris cables will reach..I mounted my Polaris contractor on the outside in my RZR 4 and it didn't last long, moisture got in it and corroded the contacts.. replaced the contractor with a Warn no problems after that. This time around I put the Viper contractor on the inside of the firewall.
 
#21 ·
I mounted my contactor behind the drivers seat above the computer. Is tight against the seat so luckily it is nearly all the way back anyway. Under the dash would have been the best spot! Wish I'd thought of that before but the wires supplied for contactor to battery didn't reach that far so I figure behind seat was good. I coated all terminals with stacks of grease (dielectric sort). I got my switch mounted on dash near headlights switch and the remote plug to the left of the steering wheel. Happy days ; )
 
#23 ·
You guys are making me nervous now! My dealer was suppose to have the winch installed on my XP when I got there to pick it up. He called me the day before I was going to go there (200 miles away) to tell me he had the wrong winch plate. I told him no biggie, I will install it myself. He is going to have it dropped shipped to my house. Now I read this thread and think to myself, "I shouls have waited an extra week" Ughhhhhh
 
#24 ·
Its easy to do, its just a pain in the ass. It will take a few hours of your time. I could do it the second time a lot quicker. I took my time the first time to make sure I did every thing correct
 
#26 · (Edited)
HIGHOCTANE:
In your opinion, how does the KFI mount compare to the Motoalliance mount? I am still bent on wanting to run a wide spool winch and was literally about to pull the trigger on the EMP mount because it will accept a wide spool winch........after reading this thread I may not.....

Has anyone installed a wide spool winch on the 900 yet??? How does it work? Does the cable end up all in the center of the spool?
 
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#27 ·
I haven't even looked at the moto alliance mount.. When I got mine moto was using EMPs mount, didn't have their own. The EMP isn't terrible.. Just could be better IMO I like hot the KFI secures the fairlead mount top and bottom and uses a roller to guide the rope to the fairlead. The way the 900 is set up the opening for the rope to pass though is offset down from the winch..the roller looks like a nice way to deal with that.
 
#29 ·
I finally received my Pure Polaris 3500 winch in a box set up for an XP today. I took everything out of the box to look it over and noticed it didn't come with a winch switch? All it has is a remote and the female end? Did they forget to put one in or does this kit not come with a switch? If it doesn't come with a switch, how difficult would it be for me to add a switch? Any help out there?
 
#32 ·
I installed the same winch on my XP last week. There is no switch like you are looking for. There is just a female pigtail to mount wherever you want. Then I just keep my remote in the glove box. Polaris does make a wireless remote that is about the size of a keyless entry for a car that will run the winch with no wires at all. I ordered one but it hasnt arrived yet. They are a little over $100. Good luck!! It was a pain in the neck job, getting big things into small places, and reaching bolts and nuts.
 
#30 ·
Not sure what you mean by a winch switch. Are you refering to the contactor? If so, it should have came with that. It also should have came with a remote socket. There should have been a list of all the parts and part numbers. I put a switch on my shifter, which is an optional item.
 
#31 ·
There should be something that says what's included in the box, probably on the first page in the instructions. Mine was supposed to have screws for the contactor and it never did, plus it had heaps of extra washers and nuts??? Can't help with the switch thing, I'm new to winches
 
#33 · (Edited)
Okay, I'll admit it.... I'm a real TARD!!!! I installed my winch plate and then installed my winch onto the winch plate (holes need to be just a tad bigger to allow for a 1/16" adjustment) and then went to install the switch block on the firewall and noticed that the wires from the winch to that block were to short..... That's when it came to me...... I INSTALLED THE WINCH BACKWARDS!!!! I'm such an idiot!

I had to remove the winch from the winch plate, turn the winch around and reinstall (it's a PITA because my hands are just to big)! I gave up for the night and will finish up the rest tomorrow.... I do have a question though; the red small wire that comes off the back of the female plug for the remote, does that go into the ignition switch? This is the 3500 Polaris winch kit.

Thanks every one!

Image
 
#39 ·
BFTD

I'm struggling to install my Moto Alliance kit. The nuts for the rear mount plate bolts seem impossible to get to. Any tips or tricks there?

I just gave up for the night.

How much effort is it to remove the front plastics as pictured above? Do you guys who did it that way think it was worth the extra effort?