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100722 - 3500 Lb. (1588 kg) WiNch

ASSEMbLY

10

 

NOTicE

Terminals coming in contact with metal will cause a 
direct short, possibly causing solenoid/contactor and/
or battery damage.

install the Rocker Switch

1.  Decide which handlebar the rocker switch will be 

mounted on. (The rocker switch is usually installed 
on the left handlebar).

2.  Use a piece of electrical tape (not provided) around 

the handlebar to help prevent rotation of the mount. 

3.  Tighten the rocker switch in place. DO NOT 

overtighten or tighten/clamp over any hoses or 
cables.

4.  Once the rocker switch is mounted, the wires can 

be routed back to where the solenoid/contactor is 
located.

5.  Make sure the handlebars have full range of motion 

and then secure the rocker switch’s cable with the 
supplied cable ties.

Wiring the Winch

 

cAUTiON

NEVER

 route electrical cables across any sharp edges, 

through and/or near moving parts, or near parts that 
may become hot.

 

cAUTiON

Battery cables should NOT be drawn tight. Leave some 
slack for cable movement.

 

NOTicE

You may need to use a test light to locate a suitable 
wire. The wire should only have power when the key is 
in the ON position.

 

NOTicE

Depending on the location of the solenoid/contactor, 
you may need to use the black and red cables in place 
of the yellow and blue, and the yellow and blue in place 
of the red and black.

1.  See the Wiring Diagram on the following page for 

these following steps. Connect the yellow and blue 
cables to the motor terminals on the winch. (Yellow 
to the positive (+) terminal of the motor. Blue to 
the negative (-) terminal of the motor). Tighten the 
terminal nuts on the motor. DO NOT over tighten. 
Route the other ends to the solenoid/contactor 
location.

2.  Connect the yellow and blue cables to the solenoid/

contactor (yellow to yellow and blue to blue). 
DO NOT tighten nuts.

3.  Connect the red and black cables to the solenoid/

contactor (red to red and black to black). DO NOT 
tighten nuts. Route the other ends to the vehicle’s 
battery.

4.  Connect the shorter red lead to the positive (+) 

terminal of the vehicle’s 12 volt battery.  Connect 
the other longer red lead to the solenoid/contactor.  
Use the supplied cable ties to attached the circuit 
breaker assembly where convenient. 

5.  Connect the rocker switch to the solenoid/contactor 

(black to black and green to green).

6.  Splice the end of the red wire on the rocker switch, 

to an ignition (keyed) controlled power source using 
the supplied wire tap.

7.  Once all wiring is connected to the solenoid/

contactor it can then be mounted using the supplied 
M6 hardware.

8.  Tighten the solenoid/contactor terminal nuts. 

DO NOT over tighten.

9.  Connect the black lead to the negative (-) terminal of 

the vehicle’s 12 volt battery.

10.  Place all terminal boots over terminals and secure 

all cables with cable ties or electrical tape (not 
included).

Summary of Contents for 100722

Page 1: ...important safety precautions which should be read and understood before operating the product Failure to do so could result in serious injury This manual should remain with the product Specifications...

Page 2: ...Mounting the Winch 9 Solenoid Contactor Location 9 Install the Rocker Switch 10 Wiring the Winch 10 Wiring Diagram 12 Switch Wiring Diagram 12 Operation 13 General Tips for Safe Operation 13 Self Rec...

Page 3: ...ercise common sense and always err on the side of caution when operating the product to ensure no accident property damage or injury occurs We want you to continue to use and be satisfied with your CP...

Page 4: ...e control and battery leads when not in use WARNING Avoid shock loads by using the control switch intermittently to take up the slack in the cable rope Shock loads can exceed the rated capacity of the...

Page 5: ...to the winch Electric winches are designed and made for intermittent use and should not be used in constant duty applications Operation Symbols Some of the following symbols may be used on this produ...

Page 6: ...rum from the gear train free spool Engaging the clutch In locks the winch into the gear system 6 Mounting Channel 7 Circuit Breaker The circuit breaker is installed as close to the battery as possible...

Page 7: ...e the synthetic rope onto the drum and minimizes damage to the synthetic rope from abrasion on the winch mount or bumper 12 Winch Connection Cables Used to connect the contactor to the winch motor 13...

Page 8: ...16 17 1 Lock Nut M10 2 1x 16mm wrench or socket Mini Rocker Switch 1 Hexagon Socket Head Screw M5 x 18 1 1x 4mm allen wrench 2 2 3 3 4 Hexagon Socket Head Screw M5 x 25 2 1x 4mm allen wrench 2 2 3 3...

Page 9: ...ighten 4 Turn winch right side up Disengage the clutch by moving the Cam Clutch Gear to the Out position the arrow on the Cam Clutch Gear would be to the back of the winch as shown Release the synthet...

Page 10: ...e in place of the red and black 1 See the Wiring Diagram on the following page for these following steps Connect the yellow and blue cables to the motor terminals on the winch Yellow to the positive t...

Page 11: ...me cable from the drum and then turn the clutch knob to the In position to engage the gears Press the cable out button on the rocker switch If the drum is turning and releasing more cable then your co...

Page 12: ...mbly 12 Wiring Diagram Blue to switch and remote wiring Yellow Black Longer Red Lead Positive Positive Negative Switch Wiring Diagram Black Green Red Ignition Wire Solenoid Contactor Battery Circuit B...

Page 13: ...with the exact specifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Store the remote control inside your vehicle in a place that it will not...

Page 14: ...tep over the synthetic rope L Double check your anchors and make sure all connections are secure M Inspect the synthetic rope Make sure there are at least 5 wraps of synthetic rope around the winch dr...

Page 15: ...inch having been Lubricated using high temperature lithium grease at the factory No internal lubrication is required Lubricate Cable Assembly periodically using a light penetrating oil Synthetic Rope...

Page 16: ...0 2000 2500 3500 KG 0 454 907 1134 1588 Line Speed 12V DC FPM 12 1 10 8 8 2 7 5 4 9 MPM 3 7 3 3 2 5 2 3 1 5 Motor Current 12V DC A 28 60 90 105 130 Running Time Minutes 5 5 5 5 5 Cooling Time Minutes...

Page 17: ...able drum does not turn Clutch not engaged Move Clutch to the In position If problem persists a qualified technician needs to check and repair Motor runs slowly or without normal power Insufficient cu...

Page 18: ...product is deemed to have been misused neglected involved in an accident abused loaded beyond the product s limits modified installed improperly or connected incorrectly to any electrical component N...

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