4500 lb winch Manual
Contents
1. KOLPIN A A A dl THE LEADER IN ALL TERRAIN INNOVATION 2500 Ib 3500 Ib 4500 Ib ATV UTV WINCH KIT P N S 25 9250 25 9350 25 9355 25 9450 OWNER S OPERATING INSTRUCTIONS SPARE PARTS Application WINCH MOUNT NO 25 XXXX OEM VEHICLE WINCH MOUNTS Before you begin please read these instructions and check to be sure all parts and tools are accounted for The following instructions contain details required to operate install and service the contents of this kit Save these instructions Important safety instructions are included in this manual O 2015 Kolpin Powersports REV 01 TABLE OF CONTENTS Introduction TARE EITE E a RR A NER ERREUR O NN ECNONS GWIGeEDOOK ae e n iia bodas Assembly MOUNINO tpm MOUNUNO e e TTT Mounting the handlebar switch 0 e ee cence ee Mounting the contactor solenoid eee e cece e Mounting the remote switch optional see ee e e ee e e nr WIN Me WIN TTT Wiring diagrami O OO RA ATV UTV Winch User GUIdE eibi adidas Winch Ma Ich Safely i FECAULONS 2 cesado STATA Kod R a Te TTT E ESL AL EAE WIE O o Ms e 1G AGING ARPA on A teneur d ica uM LED s M EE ue tte NADEL DL ELS LM EE intenance and Service Safety ee UO CIO EP odo o rn denier Cable Assembly Replacement cn 929 Ka 99 R x e d N nias 2 0 N nonini 4 AA 9 KNN NUR bl Men Kg TRO aT ETT Ferormance ee Hea TT Parts Kit Diagrams and replacement part numbers e e2. end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 4 to feed and rewind the cable evenly before continuing the winch operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again O 2015 Kolpin Powersports REV 01 9 WINCH SAFETY PRECAUTIONS continued Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch when the winch cable is under load Never use the winch for lifting or transporting people Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activ
3. itself without the help of the winch Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual 2015 Kolpin Powersports REV 01 12 WINCH OPERATION continued 12 13 14 15 Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap E Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontal
4. zinc plated m 17 Hex bolt M8 x 1 25 x 20mm zinc plated m 21 Cable black 6 gauge 36 Replacement freespool knob Part number 85072 not included with kit O 2015 Kolpin Powersports REV 01 20 TROUBLESHOOTING Problem Cause Solution l Insert switch assembly all the Switch assembly not connected properly way into the connector l Tighten nuts on all cable connections Tap contactor to loosen contacts Apply 12 volts to coil terminals directly A clicking Motor does indicates proper activation not turn Defective switch assembly Replace switch assembly Check for voltage at armature port with switch pressed If voltage is present replace winch assembly Contactor malfunctioning Defective motor Allow to drain and dry Run in Water has entered motor short bursts without load until completely dry Move freespool knob to the Motor runs but locked spool position If cable drum Clutch freespool knob not engaged problem persists a qualified does not turn technician needs to check and repair The battery is weak recharge Run winch with vehicle motor running battery should have a strong charge normal power Loose or corroded battery cable connections Clean tighten or replace Motor l E Allow winch to cool down Winch running time too long 31 de overheating periodically Mot Tap contactor to loosen DR Defective or stuck contactor contacts one direction only Repair or replace c
5. Y PRECAUTIONS N 9 or ade qe wN 29 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 14 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s center line whenever possible If winching at an angle is unavoidable follow these precautions A Lookat the winch drum occasionally Never let the winch cable stack or accumulate at one
6. ation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable O 2015 Kolpin Powersports REV 01 10 WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch TIP Consider practicing the operation and use or your winch before you actually need to use it in the field ALWAYS follow all winch instructions and warnings in this manual Improper winch use can result in SEVERE INJURY or DEATH Each winching situation is unique e Take your time to think through the winching you are about to do e Proceed slowly and deliberately e Never hurry or rush during winching e Always pay attention to your surroundings e You may need to change your winching strategy if it is not working e Always remember that your winch is very powerful e There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first three feet one meter of the winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or ser
7. cece e K WPOUDIGSMOOUNIG boina oo E RAE A RE TR Warranty O 2015 Kolpin Powersports REV 01 2 INTRODUCTION Congratulations on your purchase of a Kolpin winch The Kolpin winch works great for vehicle recovery and plow lift applications With proper use and maintenance this winch will bring many years of satisfying service Every effort has been made to ensure the accuracy and completeness of the information in this manual We reserve te right to change alter and or improve the product and this document at any time without prior notice Record the part numbers date of purchase and place of purchase for future reference Please have this information available when ordering parts and when making technical or warranty inquiries Kolpin Powersports Support 1 877 956 5746 Part Number DELTA AUS E Purchase Location GUIDEBOOK CONVENTIONS This manual uses the following symbols to help differentiate between different kinds of information The safety symbol is used with a signal word to alert you to potential hazards in operating and owning power equipment Follow all safety messages to avoid or reduce the risk of serious injury or death Each message has a specific purpose PLEASE WORK SAFELY WARNING indicates a potentially hazardous NOTICE indicates a potentially hazardous situation that if not avoided could result in situation which if not avoided may result in death or serious injury property damage NOTE If you ha
8. g NOTE For service or parts assistance contact our help line at 1 877 956 5746 O 2015 Kolpin Powersports REV 01 15 PERFORMANCE SPECIFICATIONS e Motor 12V DC permanent magnet type heavy duty GJ H ER 2500 Ib rated pull Hot lt PI A 3500 Ib rated pull Zi Se 2 s cc 4500 Ib rated pull e Motor duty cycle Intermittent e Gear reduction ratio ccc cece ccc ccecccccecceeueceeuuueeeeeenaes 166 1 e Brake Mechanical e Electric cable leads coococoocococncoccconccnonononnonanao 6 gauge e Winch cable size e 50 length x 3 16 diameter wire rope e 50 length x 7 32 diameter wire rope e 50 length x 7 32 diameter wire rope e Drum size 50mm diameter x 74mm length 2500 Ib Specifications 2500 Ib rated pull 3500 Ib rated pull 4500 Ib rated pull 4 625 117mm Line Pull Tbs Line Speed ft min Motor amps 0 1 E 239 2500 9 225 OE 400 5 E 1 P 12 8125 l 325mm 5 125 0 A A 4 5 130mm 81mm 114mm MN mM i i DI rj un gt ganeg D Y L 34 v a 4 78 86mm _ 121mm py L j Winch Dimensions Front View O 2015 Kolpin Powersports 4 875 124mm 76mm Winch Dime
9. ge 36 Cable black 6 gauge 36 22 1 Cable yellow 6 gauge 36 23 Cable blue 6 gauge 36 O 2015 Kolpin Powersports 18 REV 01 mem RPRO122 Replacement freespool knob Part number 85072 not included with kit 25 9355 Kit Contents 3500 Ib synthetic rope and Replacement Part Numbers Part Replacement Part Number ENEN I OUO O VE GE netas H w Lp esses tis Tote nan o J oo p esas a H 7 ese EE Ls o rese EE o seen H n s esee E L8 x pe ME L8 uw rese 14 86 lues nut M8 x 1 25 15 16 17 Lock washer M8 Hex bolt M8 x 1 25 x 25mm zinc plated A 2 Hex bolt M8 x 1 25 x 20mm zinc plated Terminal cap 18 19 20 21 22 22 1 Cable yellow 6 gauge 36 23 Clevis hook Cable red 6 gauge 36 Cable black 6 gauge 36 Cable blue 6 gauge 36 O 2015 Kolpin Powersports 19 REV 01 Replacement freespool knob Part number 85072 not included with kit 25 9450 Kit Contents 4500 Ib and Replacement Part Numbers Part Replacement Part Number NENEMN C OU H tr ta H ww MERO a emsmeceser Rede H m L p memes mm ENEEE ch E L7 2 eie ON Le 3 H Lm mw L8 73 ee E Ls ow sra H O RR RN a C IA EE 16 10 Hex bolt M8 x 1 25 x 25mm
10. h be installed on the left handlebar Exact position may vary depending on vehicle e Use a piece of electrical tape not provided around the handlebar to help prevent rotation of the switch bracket mount e Tighten the rocker switch in place DO NOT overtighten or tighten clamp over any hose wiring or cables e Once the rocker switch is mounted the wires can be routed to the contactor solenoid location e Make sure the handlebars have full range of motion vehicle switches brakes throttle can move freely and then secure the rocker switch s cable with the supplied cable ties e Using the provided wire splice splice the end of the red 20ga wire to a key controlled fused accessory circuit power point of the ATV UTV The wire should only have power when the key is in the ON position Hocker switch assembly Handlebar MOUNTING THE CONTACTOR SOLENOID e The contactor solenoid is a primary safety feature in the winch system It disconnects the winch from its power source when the vehicle is not in use The contactor solenoid must be correctly installed to work properly e Find a location for the contactor solenoid It is recommended that the contactor solenoid be mounted close to the battery in a clean dry location The exact location of the contactor solenoid will vary depending on the vehicle Make sure the location chosen allows for sufficient clearance from all metal components such as frame tubes DO NOT place tools or other ite
11. ith a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used 6 Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading O 2015 Kolpin Powersports REV 01 14 WINCH MAINTENANCE AND SERVICE SAFETY ALWAYS follow all winch instructions and warnings in this manual Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware 2 Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to p
12. lled accessory circuit of the ATV UTV as described in the above step ALWAYS make sure to splice into keyed accessory WIRING THE WINCH wire that has power when key is turned on You may need to use a test light to locate a suitable wire Install the wiring using the diagram on the next page Slip terminal boots on yellow and blue cable ends Connect the yellow and blue cables to the color matched motor terminals on the winch Tighten the terminal nuts on the motor DO NOT overtighten Seat boots over terminal Route the other ends to the contactor solenoid location Connect the yellow and blue cables to the contactor solenoid yellow to yellow and blue to blue DO NOT tighten nuts or seat boots at this time Slip terminal boots on the ring terminal ends of the black and red cables Connect the black and red cables to the contactor solenoid red to red and black to black DO NOT tighten nuts or seat boots at this time Route red and black cables to battery DO NOT connect cables to battery at this time Mount the contactor to the location planned in the previous steps with provided hardware Tighten the contactor solenoid mounting fasteners DO NOT overtighten Adjust cables to facilitate orderly and straight routing of the cables from the contactor solenoid Avoid kinks or sharp bends in the cables Avoid crossing cables over each other for at least the first 6 of cable starting from the contactor solenoid post Tighten the contactor
13. ly to evenly dis tribute the winch cable on the drum F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable WINCH CABLE CARE For your safety always replace KOLPIN winch parts including the cable with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website Kolpin com NEVER use a worn or damaged cable Use of a worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 2 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Akinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right Promptly discontinue use of a winch cable i
14. ms in a position that might come in contact with the contactor solenoid posts e Drill mounting holes if required Secure the contactor solenoid using the provided hardware e Once a location is found for the contactor solenoid DO NOT install the unit until all wiring is completed see wiring section Pre fit all wiring to confirm its long enough to reach the battery and the winch contact locations NEVER short battery terminals with metal objects Be aware terminals in contact with metal will cause a direct short possibly causing contactor solenoid and or battery damage O 2015 Kolpin Powersports REV 01 6 MOUNTING THE REMOTE SWITCH optional on some models Determine the mounting location for the remote socket Exact position may vary depending on vehicle Drill three holes and install to vehicle dash panel or body panel Route the wire harness to where the contactor solenoid will be mounted Secure the socket s cable with the supplied cable ties Using the provided wire splice splice the end of the red 20ga wire to a key controlled accessory circuit power point of the ATV UTV or use the provided 20ga wire eyelet terminal connector to connect to a vehicle terminal strip post The wire should only have power when the key is in the ON position NOTE If installing both switches handlebar rocker and corded remote both 20ga red wires must be connected together with the provided plug connectors or spliced to a key contro
15. n this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth sist X Y ei Ki A P or glazed Promptly discontinue use of a winch cable in this o REA PAN E condition p Mn O 2015 Kolpin Powersports REV 01 13 SHOCK LOADING NEVER shock load a winch cable Your winch cable is very strong but itis NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It generates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable NEVER use a broken winch cable SEVERE INJURY or DEATH can result 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object w
16. ns are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation With some applications the motor terminal posts may need to be rotated to avoid interference with other components NEVER route electrical cables across any sharp ALWAYS leave some slack for electrical cable move edges through and or near moving parts or near ment Battery cables should NOT be drawn taut parts that may become hot O 2015 Kolpin Powersports REV 01 T WIRING DIAGRAM Attach to blue T terminals Attach to positive battery terminal Y Attach to yellow terminals n Attach to Connect to negative switch harness battery terminal in Contactor solenoid Use wire splice connector to splice switch harness red wire to a key controlled accessory circuit wire on the vehicle O 2015 Kolpin Powersports REV 01 8 ATV UTV WINCH USER GUIDE Before you begin using your winch read and understand the guide Please retain this guide for future reference These safety warnings and instructions apply if you choose to add an accessory winch to your vehicle ALWAYS follow all winch instructions and warnings in this manual Improper winch use can result in SEVERE INJURY or DEATH Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise WINCH SAFET
17. nsions Bottom View 16 REV 01 25 9250 Kit Contents 2500 Ib and Replacement Part Numbers Part Replacement Part Number ENEN COLD a netas H ww L3 po opn ct sto 37ers Tega RENE I MMEAMMMMMMNMNNENMMNNNN JN 1 3 pen H 7 ese EE Ls o rese EE o seen H n s esee E L8 x pe ME 13 10 Flat washer M8 14 86 lues nut M8 x 1 25 15 16 17 Lock washer M8 Hex bolt M8 x 1 25 x 25mm zinc plated A 2 Hex bolt M8 x 1 25 x 20mm zinc plated Terminal cap 18 19 20 21 22 Clevis hook Cable red 6 gauge 36 Cable black 6 gauge 36 22 1 Cable yellow 6 gauge 36 23 Cable blue 6 gauge 36 O 2015 Kolpin Powersports 17 REV 01 mem RPRO122 Replacement freespool knob Part number 85072 not included with kit 25 9350 Kit Contents 3500 Ib and Replacement Part Numbers Part Replacement Part Number ENEN I OUO O VE GE netas H L3 po rine ct sto T2760 T RENE I MMEAMMMMMMNMNNENMMNNNN JN 1 3 pen H 7 ese EE Ls o rese EE o seen H n s esee E L8 x pe ME 13 10 Flat washer M8 14 86 lues nut M8 x 1 25 15 16 17 Lock washer M8 Hex bolt M8 x 1 25 x 25mm zinc plated A 2 Hex bolt M8 x 1 25 x 20mm zinc plated Terminal cap 18 19 20 21 22 Clevis hook Cable red 6 gau
18. o Tread Lightly amp treadlightly org KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website 10 Vis E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch Never remove the hook strap from the hook Release the winch clutch and pull out the winch cable YES NO Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Alway
19. on on the winch mount or bumper Used with steel cable Aluminum Non Roller Fairlead Provides smooth edge to guide rope onto the drum Used with synthetic rope O 2015 Kolpin Powersports 4 9 Wire Rope Galvanized aircraft cable designed specifically for winch load capacities 10 Winch Connection Cables Used to connect the contactor to the winch motor 11 Battery Connection Cables Used to connect the battery to the contactor 12 Clevis Hook Provides a means for connecting the looped ends of cables to an anchor 13 Strap Used to assist cable feed 14 Contactor solenoid Power from the vehicle battery flows through the weather sealed contactor solenoid switch before being directed to the winch motor 15 Rocker Switch Rocker switch with handlebar mount for powering the rope in or out of your winch drum 16 Corded Remote Switch Corded remote switch allows the operator to stand clear during the winching process Supplied with 4500lb winch kit REV 01 ASSEMBLY The winch kit comes mostly assembled from the factory Some pre assembly of the kit is required for installation into vehicles BEFORE YOU BEGIN Your Kolpin accessory is designed for a universe fit for most vehicles Please read and understand all instructions Verify all parts and tools are accounted for To ensure a satisfactory installation follow all steps cor rectly and in the sequence described To facilitate ins
20. ontactor Defective switch assembly Replace switch assembly Motor runs slowly or Insufficient current or voltage without NOTE For further technical support contact our help line at 1 877 956 5746 2015 Kolpin Powersports REV 01 21 KOLPIN THE LEADER IN ALL TERRAIN INNOVATION Five Year Mechanical Limited Warranty and Three Year Electrical Limited Warranty From the original purchase date Kolpin Powersports warrants to the original purchaser the mechanical components of the winch will be free of defects in material and workmanship for a period of 5 years and the electrical components will be free of defects in material and workmanship for a period of 3 years This warranty does not apply to wire rope synthetic rope or parts that have been damaged by accident misuse alteration improper service normal wear or causes beyond the manufacturer control To obtain warranty service call 1 877 956 5746 to request a Return Merchandise Authorization RMA number and shipping details This warranty does not cover removal or reinstallation labor fees of the winch All transportation cost of submitting product to Kolpin for warranty consideration are the responsibility of the shipper Kolpin Outdoors Inc Telephone 763 478 5800 Toll Free 877 956 5746 Fax Number 800 245 7569 www kolpin com customerservice kolpin com 2015 Kolpin Outdoors Inc REV 00 22
21. revent accidental activation of the winch 4 For your safety always replace KOLPIN winch parts including the cable with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website Kolpin com 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching ALWAYS be aware that failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH LUBRICATION All moving parts within the electric winch have been lubricated using high temperature grease at the factory No internal lubrication is required Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable CABLE ASSEMBLY REPLACEMENT It is recommended that only KOLPIN supplied parts be used 1 Move the clutch to the free spool position 2 Extend cable assembly to its full length Note how the existing cable is connected to the inside of the drum 3 Remove old cable assembly and attach new one 4 Retract cable assembly onto drum being careful not to allow kinkin
22. s release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn The ONLY time a winch equipped vehicle should be moving when using the winch is when the vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 14 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable Align the winch cable as close as possible to the winching vehicle s center line Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual Re engage the clutch on the winch Slowly winch in the slack in the winch cable Select the proper vehicle gear to propel the stuck vehicle in the direction of winching Shift to the lowest gear available on the stuck vehicle comm OO uU Slowly and carefully apply vehicle throttle and winch together to free the vehicle Stop winching as soon as the stuck vehicle is able to propel
23. solenoid terminal nuts DO NOT over tighten Seat terminal boots over ring terminals and posts Connect the rocker switch to the contactor solenoid using the provided plug Splice the end of the red wire on the rocker switch to a vehicle accessory circuit controlled by ignition controlled power source keyed The wire should only have power when the key is in the ON position Carefully inspect battery and winch electrical cable routing to ensure it is neat and tidy Secure electrical cables and wiring harnesses with provided cable ties Cable ties should be snug but not cutting into wire insulation Use electrical tape pieces of rubber hose or electrical conduit to protect electrical cables and wire harnesses where needed to avoid electrical cable insulation wear or abrasion Connect the red lead to the positive terminal of the vehicle s 12 volt battery first Connect the black lead to the negative ter minal of the vehicle s 12 volt battery second Install protective boots as appropriate to protect connection Tighten battery terminal fasteners as directed in the vehicle service manual to the proper torque specification Check for proper drum rotation Pull and turn the clutch knob to the free spool position Pull out some cable from the drum and then turn the clutch knob to the locked spool position to engage the gears Press the cable out button on the rocker switch If the drum is turning and releasing more cable your connectio
24. tallation make sure that your vehicle is clean and free of debris All directions referring to right and left are when the rider is sitting on the machine MOUNTING THE WINCH e f using a winch mounting kit refer to the kits manual for specific instructions e Mount the winch to the mount plate as shown below Rotate the lock knob to the free spool position and feed the winch cable through the rollers of the roller fairlead e Mount the roller fairlead plate and attach the hook clevis and nylon pull strap Rotate the lock knob back to the lock position ALWAYS ensure that the 3 major sections motor drum gear housing are properly aligned if utilizing a mounting plate Proper alignment of the winch will allow for even distribution of the full rated load Roller fairlead or aluminum hawse orientate warning label to face upwards or outwards so it is visible when viewing from front of vehicle Clevis 1 hook O 2015 Kolpin Powersports 9 Use two M8 1 25 x 20mm bolts to attach fairlead TOOLS REQUIRED Basic metric wrench set Basic metric socket set Pliers Philips screwdriver ALWAYS use supplied hook strap d Rotate to lock or un lock spool x Use four M8 1 25 x 25mm bolts to attach winch REV 01 MOUNTING THE HANDLEBAR SWITCH e Install the rocker switch to the handlebar using the hardware included in this kit as shown below e tis recommended that the switc
25. ve questions regarding your winch we can CAUTION indicates a potentially hazardous help Please call our help line at 1 877 956 5746 situation that if not avoided may result in minor or moderate injury O 2015 Kolpin Powersports REV 01 3 CONTROLS AND FEATURES Read this owner s manual before operating your winch Familiarize yourself with the location and function of the controls and features Save this manual for future reference WINCH 1 2 3 4 5 6 7 8 Motor 12V DC motor provides power to the planetary gear mechanism Braking System Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the winch cable Winch Drum The winch drum is the cylinder on which the wire rope is stored It can feed or wind the rope depending on the remote winch switch signal Planetary Gear System The reduction gears convert the winch motor power into extreme pulling forces This system allows high torque while maintaining compact size and light weight Free Spooling Clutch The clutch allows the operator to manually disengage Out the spooling drum from the gear train free spool Engaging the clutch In locks the winch into the gear system Mount Assembly Flatbed mounting channel Roller Fairlead When using the winch at an angle the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasi
26. vice 3 Always apply your vehicle s parking brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 4 Always use the hook strap when handling the hook NEVER put your fingers into the hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable TIP A tow strap is NOT intended to stretch A recovery strap is designed to stretch NEVER use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 14 O 2015 Kolpin Powersports REV 01 11 WINCH OPERATION continued B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure C If possible keep the winch cable aligned with the center line of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead ALWAYS replace the winch cable at the first sign of D If freeing a stuck vehicle by attaching to a tree use an item such as a damage to prevent SEVERE INJURY or DEATH in tow strap to avoid damaging the tree during winch operation Sharp the event of a failure For your safety always replace cables and chains can damage and even kill trees Please remember KOLPIN winch parts including the cable with t
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