©2021 Copyright Kappers Fabricating, Inc. All rights reserved
Page 1
POLARIS SPORTSMAN XP
WINCH MOUNT
Winch Mount
PART # 101840
Hardware Kit: HK-338
Kit Components:
INSTALLATION INSTRUCTIONS:
1. Assemble the Hawse or Roller Fairlead (not included)
to the mount as shown using the supplied 3/8” x 3/4”
carriage bolts (9) and nuts (10) “
shown in figure 1”
.
2. If you are planning on installing a Polaris Glacier
Plow please install the included 3/8” x 1” carriage
bolts (13) and nuts (14) at this time to the lower
square holes. “
Shown in figure 1
”
3. Remove any accessory front brush guards if
equipped.
4. Remove the front plastic:
550/850 XP:
Remove the bolts “
shown in Figure 2”
and remove the plastic. Loosen the 2 bolts as
“shown
in Figure 3”
and rotate the metal cover downwards
to allow for room to install the winch assembly. If
preferred, you can remove the metal/plastic cover in
Figure 3 by removing the upper hardware.
400/450/500/570/800:
Remove
the bolts
“shown
in figure 2”
and
remove the front plastic. Cut out
section (A) “
shown in Figure 2”
.
5. Remove the seat, disconnect battery, and remove the
front rack.
6. Disassemble the light pod.
7. Remove access panel under light pod.
Item Qty. Description
1
1
Winch Mount
2
1
Bracket - Contactor Mount
3
4
M8-1.25 x 25MM Hex Head Bolt 8.8 Zinc
4
4
5/16” S
AE
Flat Washer Zinc
5
4
5/16” Lock Washer Zinc
6
2
1/4”-20 X 1” Hex Bolt GR5 Zinc
7
4
1/4”-20 Nylock Nut
8
2
1/4” SAE Flat Washer Zinc
9
2
3/8”-16 X 3/4” Shortneck Carriage Zinc
10
2
3/8”-16 Nylock Nut
11
1
M6X1.0 X 18MM Hex Head GR5 Zinc
12
1
Male Disconnect .250 X .032 22-18GA Insulated Red Vinyl
13
2
3/8”-16 X 1” Short Neck Carriage Bolt GR5 Zinc
14
2
3/8”-16 Nylock Flanged Nut GR5 Zinc
15
2
1/4”-20 X 1-1/2” Hex Flg Self-Tap Screw Zinc
16
2
1/4”-20 X .75” Carriage Bolt GR5 ZP
“
Figure 3
” Loosen Bolts
550/850 XP
13
4 5 3
14
1
2
7
16
9
10
Standard 4-hole mounted winches
mount upside down per polaris design.
If you have a 2-hole mounted winch you
will use the (2) holes in the center of the
top surface.
Cable must come off the bottom
of the winch as shown.
“
Figure 1
” Exploded View
“
Figure 2
” Removal of Front Plastic
A
