Instr 26-3200; 26-3210
Rev 01 2020-11
Page 15 of 17
TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSES
RECOMMENDED SOLUTION
Winch will not operate.
Contactor not receiving power.
Turn vehicle key ON.
Connections between components not in
proper order.
Check connections. Connect wired
handlebar switch connection from
vehicle main wire harness directly to
contactor to make sure a direct
connection will operate the winch. If
connections are not in the order shown
in the pictures on the last page, the
whole system may not function, or only
certain parts of it will function.
Loose battery cable connections.
Tighten nuts on all cable connections.
Keyed power circuit (orange wires) not
properly powered.
Check fusebox for 10A accessory circuit.
Check voltage in certain places,
especially orange wires coming out of
the main harness by the steering post.
Contactor malfunctioning.
Tap contactor to loosen contacts. Apply
12 volts to coil terminals directly. A
clicking indicates proper activation.
Defective switch assembly.
Replace switch assembly.
Defective motor.
Check for voltage at armature port with
switch pressed. If voltage is present,
replace winch assembly.
Nested and bounded cable within winch
assembly.
Move free spool knob to the “free spool”
position. Manually pull cable out of winch
until end is met and then re-spool cable
back into winch.
Water has entered motor.
Allow to drain and dry. Run in short
bursts without load until completely dry.
Winch makes noise,
but rope does not
move.
Contactor powered, but not winch.
If you can hear a clicking sound when
you press the winch control, but the
winch does not make any sounds, check
the connections between the winch and
the contactor.
Winch not in proper gear.
Move free spool knob to the “locked
spool” position, then recheck. If problem
persists, a qualified technician needs to
check and repair.
Winch operates too
slowly.
Winch improperly loaded.
Check that the winch is clear and the
rope is not bound up.
Insufficient current or voltage.
The battery is weak, recharge. Run
winch with the vehicle motor running
(battery should have a strong charge).
Loose or corroded battery cable
connections.
Clean, tighten, or replace.
Winch overheating.
Winch running time too long.
Allow winch to cool down periodically.
