| Warn Industries, Inc.
Step Two: Winch Mounting
ATV winch mounting kits are available from your
Warn Dealer to satisfy nearly all ATV applications.
For information on available kits, contact your
WARN product dealer.
To secure the winch, always use:
• A flat, secure mounting location at least 3/16 in.
(4.8 mm) thick.
• 5/16 in. (8mm) Lock washer.
• Must use the 5/16-18 x 1 in., grade 5 hex head
cap screws supplied.
• Torque mounting bolts to 12 ft-lbs (1.7 kg-m).
Attach the clevis hook to the wire rope at this time.
• Put clutch in freespool position.
• Manually feed cable loop through fairlead.
• Attach hook to cable loop and re-engage clutch.
Step Three: Contactor Location
• The contactor is a primary safety feature in your
winch system. It disconnects your winch from its
power source when the ATV is not in use. The
contactor must be correctly installed to work
properly.
• It is recommended that the contactor be
mounted close to the battery and in a location
that is as clean and dry as possible. Exact
location will vary, depending on the ATV. Usual
locations include inside, on top, or on the side of
rear storage box, and on a few models, under
the seat.
• Ensure the contactor mounting location selected
provides sufficient clearance from all metal
structures such as frame tubes. DO NOT place
tools or other items in a position that might come
in contact with the contactor directly.
• Drill the mounting holes for the contactor at this
time, then move on to step four as it will be
easier to attach all the wiring to the contactor
before attaching it to the ATV. DO NOT mount the
contactor at this time.
Figure 5. Contactor for the
WARN ATV winch
Figure 4: Orientation of winch to
mounting plate.
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WARN 2.5ci Winch Installation and Specification Guide |
Step Four: Handlebar Switch
Installation
WARNING!
TO PREVENT SERIOUS INJURY OR DEATH FROM
ELECTRICAL FIRE:
• Do not route electrical cables across sharp edges.
• Do not route electrical cables through or near
moving parts.
• Do not route electrical cables through or near
any high heat parts.
• Avoid pinch and wear/abrasion points when
installing all electrical cables.
TO AVOID INJURY AND PROPERTY DAMAGE:
• Use caution when moving or repositioning any
vehicle controls so as to not compromise the
safe operation of the ATV. Select a mounting
position that will provide clearance for all
vehicle controls.
• Before securing the switch cable with tie
wraps, make sure that the handlebars have full
range of motion.
• It is recommended that the switch be installed
on the left handlebar. A piece of electrical tape
around the handlebar will help prevent rotation of
mount on the handle bar.
• Do not tighten over any hoses or cables.
• Once the handle bar switch is mounted, route
the two bullet terminal wires back to where the
contactor will be mounted. Splice the end of the
red 20ga wire to a key controlled electrical wire of
the ATV. Using a test light, locate a suitable wire
from the ATV key switch. The wire should only
have power when the key is in the "ON" position.
Figure 6: handlebar mount. Exact positioning
may vary depending on ATV make and model.
Figure 7: Mini-rocker switch assembly.
Figure 8: Use a test light to locate
a suitable wire.
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