ATV Winch Installation Guide – Step By Step

By Richard Robertson | Automobile

ATV Winch Installation Guide

What if your car got stuck somewhere and you could not manage it to move even a little? It is obvious you will not leave without your car. So what will you do to get it back to home? If there is an installed winch in a car, then it will be no longer a problem moving your vehicle.

A winch is a device which is used to let out or pull in an object. These actually used on the backstage of a theater for moving the sceneries, to move heavy objects, currently used for water and also for snow sports. Moreover, there’s usually a rope with the winch stored on.

When we talk about ATV, placing it on the front bumper is better. Be careful when moving the plate and wire so that your ATV is not damaged. So some steps and precautions should maintain when you are installing a winch. This is because serious damage can occur to you or your machine when installing.

Necessary Parts And Tools

1. Mounting plate

2. Flat washer

3. Bolt (sizes of the bolts will be according to the model of ATV)

4. Spacer

5. Wrenches

6. Ratchet

7. Drill

8. Socket

Mounting The Plate

1. First, remove the plate in front of the front bumper by removing bolts. There are four bolts in the front; these are securing the plate. Then remove the side bolts, four in numbers from each side. When you are unscrewing the center bolt, use a screwdriver. Save the bolts as these will need to reinstall the plate skid.

2. Two bolts maintain the position of the front plastic fascia. It attaches to the front bumper. Remove these bolts also. Remove top bumper bolts (2), bottom bumper bolts (2). These will need to reinstall the plate, so save the fasteners. Then remove middle bumper bolts (2).

3. Attach roller fairlead using nuts, bolts and lock washers. Tight the bolts to a specific torque.

4. With four fasteners and lock washers, mount the winch to a bracket. And then tight the bolts.

5. Place the plate, winch and roller fairlead on the front bumper according to their position. Reinstall all the bolts that you have unscrewed when uninstalling and at a recommended torque, tighten the bolts.

6. Attach clevis hook to the cable loop.

So, this is the end of winch installation.

Warnings and cautions

  •  Secure mounting location – 4.8 mm thick.
  • Check your line because it should have an unobstructed path.
  • Tighten all bolts securely.

Wiring the winch

1. There is a contactor which is like a relay box use in winches, and its position is on the right side of a rear tool box.

2. A wire harness is attached to a bracket, and the bracket holds this into its place. First, remove it. For this, you have to remove the rivet heads using drills and drill bit.

3. Then relocate the harness using a zip tie.

4. Place the contactor for positive red cable. Position it in the lower left corner where there will attach a handlebar switch. Before securing the contactor, drill holes for placing it. Secure it with bolts, lock washers, washers, and nuts. Four bolts will need for positioning. Then tighten the nuts.

Warnings and cautions

  • Leaning over battery and shortening of battery terminals should not be done.
  • Avoid mounting of the wiring of the winch near the heat source.
  • The area where you are drilling should clear of the fuel tank, electrical wires as well as brake lines.

Installation of handlebar switch

1. For installing a handlebar, first route the positive or red cable. If the distance between the electrical wire and the red wire is 25 cm or 10 in., then it is better.

Besides, you will able to see the route of the red wire through which the red cable protrudes. The wire protrudes towards the switch case.

2. The location of the switch is under the handlebar.

3. Splice the switch into the wire which is pink and in the ignition switch wire. Before this, remove bolts and cut the protective cover over the harness. Moreover, there should be no power presence in the pink wire. Otherwise, the hazard may cause.

4. By removing bolts, remove side panels.

5. When you are keeping all the parts together like before the mounting, keep eyes over other original wires that those remain in the previous position. To secure handlebar switch, use plastic straps.

6. Tighten the fasteners and reinstall the cowl which you removed at very early of the installation.

Warnings and cautions

  • Routing across sharp edges of electrical cables should avoid.
  • Do not route the cables near moving parts and parts that get hot.
  • Avoid excess tightening of bolts.

Installation of wiring

1. Connect the blue and yellow wires and route to the ATV after connecting to the contactor. Routing should be along the frame tube. Then attach these to the motor terminals. Ties the cables to secure.

2. Like the yellow and blue ones, connect red and black cables to the contactor. Route the cables from contactor and instead of ATV connect these to the battery. Through the holes of the battery compartment, the cables can enter into the battery. Here also use cable ties.

3. Attach red cable to the contactor which is red and black cable to the black. The red one is the positive terminal, and the black one is the negative terminal.

4. After installing all the parts, install the seat as before.

Warnings and cautions

  • Abrasion points should avoid.
  • Routing near moving parts should avoid.
  • Insulate all the electrical terminals

Safety instructions

  • Wear safety glasses or flying chips can harm your eyes.
  • Insulate all the wires.
  • Terminal boots should install.
  • At the time of cutting and trimming, use extreme precautions.
  • Remove jewelry.
  • Leaning over battery should avoid.
  • Electrical cables should not route through moving parts and across sharp edges.
  • Ensure the security of all the components.

Final verdict

Above procedure of installing ATV winch is the easiest one. But for not taking and maintaining the cautions strictly is the cause of hazards.

Over this, if you know the installation then you would not need outside help, and you can help yourself. So taking the proper safety, you can easily install a winch, and you will be beneficial.

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