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Discussion Starter · #1 ·
I have a 3500# winch from Polaris. While plowing this winter the controller would quit working occasionally just on the IN button. It has worked fine for a couple months and is now acting up again. Is there a way to find out if this is the controller or the selenoid?
 

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Had the same problem, it is with the contactor, the black box where the four large wires and the two small ones. I searched for winch contactors and found a close replacement by a company called (I think) KDS or some three letter company for about 27.00$. The only mod you will need to do is to change the connectors on the small wires. Works great,
John
 

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My Polarass 3500 lb winch failed the first time I REALLY needed it. Had to use the synthetic cable as a tow rope attached to another bike and it broke 7 times and even broke twice as it was doubled up. Not as strong as I had hoped. Dealer went good and checked it over. They replaced the line and discovered it was just a blown fuse. LOL. In defense of the blue synthetic rope we were getting a run on and snaping it tight to get me out of the bog.
 

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My Polarass 3500 lb winch failed the first time I REALLY needed it. Had to use the synthetic cable as a tow rope attached to another bike and it broke 7 times and even broke twice as it was doubled up. Not as strong as I had hoped. Dealer went good and checked it over. They replaced the line and discovered it was just a blown fuse. LOL. In defense of the blue synthetic rope we were getting a run on and snaping it tight to get me out of the bog.
lol! Well at least we know how tough these winches are now, no damage to it at all other than the line?
 

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My Polarass 3500 lb winch failed the first time I REALLY needed it. Had to use the synthetic cable as a tow rope attached to another bike and it broke 7 times and even broke twice as it was doubled up. Not as strong as I had hoped. Dealer went good and checked it over. They replaced the line and discovered it was just a blown fuse. LOL. In defense of the blue synthetic rope we were getting a run on and snaping it tight to get me out of the bog.
lol! Well at least we know how tough these winches are now, no damage to it at all other than the line?
Yep just the line. I guess I should find where the fuse goes and start carrying a couple extra with me. It's a new bike and winch so I would like to know why the fuse blew so quick. I used it once before to pull a friend out.

RzR winches are basicly ATV retrival devices. LOL
 

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There is actually two seperate circuits for a winch. One is the large power circuit that isn't fused that should be wired fom the battery and goes thru the contactor which determines which way and when the winch rotates.
The other one is the control circuit that is powered off the conector under the dash and is fused. this circuit takes the input from the in-out switch and tells the contactor what to do. What some peopls don't realize is with this wiring the key needs to be on tho power this control circuit. In the rush to use the winch some haver turned off the engine, released and connected the cable-rope then pushed the in switch only tohave nothing happening due to the key being off.
John
 

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Add me to the list. except my winch is a warn. I am also having an issue that occurred twice, where it stays in free stool. it will turn in an out but as soon as you pull tension it will not spool in or out. It has been sent back twice and again I have an issue. I am also having the issue listed here. Mine makes a clicking noise in the distribution box on the fire wall, but will not spool in. I am jut going to buy a new non Polaris or warn winch and take my chances.
 

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Discussion Starter · #8 ·
Is there a way to jump the selenoid in case of emergency, or with this possibly blow up the winch. I have had starter selenoid on Ford (Fix Or Repair Daily) go bad and was able to jump the selenoid.
The rope Polaris gives you is JUNK! I have broken 15-20 ft. off just from plowing. It has broke everywhere from right @ the hook to inside the winch and everywhere in between.
 

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Rich, yes you can jump the contactor, it you look @ the wiring on The Contactor (the black box on the firewall. There are two large wires from the winch and a red wire that comes from the battery. If you jump from the red battery wire to one of the winch wire the winch should go in (or out) the other one will be the oposite. Check this out in a non-treating time with the rope (wire) partially spooled out. I also recall something about using the right fairlead and/or wire/rope to prevent repative breaks. I know that doesn't help much but someone has walked (or should I say, plowed ) down that path,
John
 
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My Polarass 3500 lb winch failed the first time I REALLY needed it. Had to use the synthetic cable as a tow rope attached to another bike and it broke 7 times and even broke twice as it was doubled up. Not as strong as I had hoped. Dealer went good and checked it over. They replaced the line and discovered it was just a blown fuse. LOL. In defense of the blue synthetic rope we were getting a run on and snaping it tight to get me out of the bog.
lol! Well at least we know how tough these winches are now, no damage to it at all other than the line?
Yep just the line. I guess I should find where the fuse goes and start carrying a couple extra with me. It's a new bike and winch so I would like to know why the fuse blew so quick. I used it once before to pull a friend out.


RzR winches are basicly ATV retrival devices. LOL
They come with a couple of spare fuses in the fuse box...
 

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Just some additional info. Its also a good ideal to check the heavy cable connections on occasion to make sure they are tight and have no rust. Loose connections and/or rust cause higher resistance witch intern causes higher operating currents that reduce the capacity of the winch. It will also cause decreased battery and/or Winch motor life and/or failure.
 

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Add me to the list. except my winch is a warn. I am also having an issue that occurred twice, where it stays in free stool. it will turn in an out but as soon as you pull tension it will not spool in or out. It has been sent back twice and again I have an issue. I am also having the issue listed here. Mine makes a clicking noise in the distribution box on the fire wall, but will not spool in. I am jut going to buy a new non Polaris or warn winch and take my chances.
That free spool would be a clutch issue. Warn Winch's are the best in the Industry IMHO. Ramsey would be my second choise. Stay away from the cheaper China units.
 

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Is the Polaris contactor the only contactor that will work on the 3500 winch. I found a KFI 4469 that looks identical, for around $35. I tried to contact Fix My Toys on the internet they show this KFI contactor with a OEM Polaris label next it? But cannot get anyone one on the phone. I left a message for a call back, it's been a few hrs not a call back as of yet..

http://www.fixmytoys.com/servlet/the-4897/4469-AFTERMARKET-4469-KFI/Detail
 

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Thanks, John I called KFI Products, and they said it would work as well. They did not mention the reversing of the wires, but that should be no problem. I did find it at Amazon for less $31.30 with free ship. [ame]http://www.amazon.com/KFI-Products-ATV-CONT-Replacement-Contactor/dp/B0027UPPK6/ref=sr_1_1?s=automotive&ie=UTF8&qid=1341003620&sr=1-1&keywords=kfi+contactor[/ame]
 

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Thanks, John I called KFI Products, and they said it would work as well. They did not mention the reversing of the wires, but that should be no problem. I did find it at Amazon for less $31.30 with free ship. Amazon.com: KFI Products ATV-CONT Replacement Winch Contactor: Automotive
OK. Breeze Lawn & Garden where I bought the Polaris 3500 winch tried to get Polaris to replace the contactor as a no charge, but Polaris has refused,:rm_thumbdown: even though Polaris admits the contactor was problematic, they still will not replace it, because it is a couple of months out of warranty, even though it was brand new, and failed the 1st time I needed it. Polaris has since changed the contactor because of repeated failures of the old design to a up-dated one which is priced at $100 dollars, or more. So I have bought the KFI at a fraction of the Polaris one $31.30. which works great. I certainly would not recommend the Polaris 3500 winch, and most likely,my next one will be a Warn.
 
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