INSTALLING A WARN/POLARIS WINCH IN 21 STEPS

Step 1: At the front of the ATV, reach in and pull off POLARIS plastic front cover. (should snap right off)

Step 2: Remove 4 bolts that secure the front assembly (two are visible after removal of plastic cover removed in step 1)

Step 3: Remove headlight connectors (2) and remove entire front bumper/grill assembly - set aside.

Step 4: If winch is not already mounted to ATV specific plate, do this now, and then bolt winch plate to the front of ATV using 4 self tapping bolts included with winch/plate.

Step 5: At this point you can reattach the front assembly(using the 4 bolts you removed) and headlight connectors.

Step 6: Open front cargo box and remove access panel over radiator, then remove plastic access panel under top headlamp.

Step 7: Fish the two colored cables from the winch(should be blue and yellow) over the radiator and into the front of the headlamp (should be lots of wires in there)

Step 8: Mount the thumbswitch to the handlebars by removing the 2 hex bolts that hold on the headlight switch. Place the spacers between the thumbswitch mount and the headlight switch mount and use the longer bolts that should be included to secure.

Step 9: Remove the single headlamp cover. (3 phillips head screws) and run the wires from the thumbswitch down the bar and into the headlight area and down to where you ran the two winch cables. Re-attach headlamp cover.

Step 10: Remove the seat and both black side covers (it isnt necessary to remove the side covers but they attach easy and it makes it easier to get to everything.)

Step 11: Turn the ATV handlebars to the left and look under the right side of the ATV behind the wheel and up near the frame you will see a silver colored plate held on by two bolts. Remove the two bolts and pop off the two cable attachers so that the plate comes completely out.

Step 12: Fish the two winch cables and the wire with the pod on it from the thumbswitch down to the area where you removed the silver plate. (the only cable that gets left behind is the small one with the spade end-we'll get to that in a minute)

Step 13: Attach the Winch Solenoid to the plate using bolts included with the winch.

Step 14: There should be two cables that were behind the plate(mine were in a rubber sheath) I think they are Red and Purple. Pull these out and run these two cables and the two from the winch through the hole in rubber case that came on the top of your solenoid.

Step 15: Attach all 4 cables to the solenoid. The red and purple ones should go on the 2 center leads and the blue and yellow cables from the winch should go on the outside leads- tighen all .

Step 16: Attach pod from thumb switch to male end from solenoid. Pull rubber solenoid cover over the solenoid (covering the leads)

Step 17: Re-attach cable attacher to plate (i think it holds the choke cable- or rear brakes-I dunno) then re-attach plate to frame with the two bolts. -tighten. (you're done under here now)

Step 18: Back up top - Find the single spade ended cable coming from the thumbswitch and you should be able to attach it to a orange cable (with a female spade end) which will be under the main headlamp (where all the wires are) Wrap connected spade with electrical tape.

Step 19: Make sure that none of the wires are pulling too hard on others and replace the plastic cover under the headlamp and the one in the cargo box. Close cargo box lid.

Step 20: Go to the left rear of ATV and find the single cable between the battery seat and the air box. FIsh this out and attach to the positive lead on the battery (this was a pain for me - cable is stiff and you have to fish it back towards the front of the ATV before you can pull it back to the batery and attach it.)

Step 21: Replace both side covers and seat. - Start up ATV and give her a whirl!!

This is all from memory but I just did it yesterday so its all still fresh.

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2005 Polaris SP 500 H.O
L&R Cargo box and Bags
2500# Polaris Winch
Swisher plow/bucket

2005 Yamaha Wolverine 350
2006 Kawasaki Bayou 250
2005 Kawasaki KFX80

Install a Warn/Polaris Winch in 21 steps

wow, thats alot of typing lol. you should put that in your favorites so when some one ever ask that question you'll have it. good info

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08' sportsman 800 w/ most of the goodies from the 06' traded- 06 sportsman 800 w/itp type 7 wheels and 27"xtr mudlites 3.0 warn, brush gaurd and rear bumper dalton clutch spring. 08' sportsman 400 w/ 25"swamplites and rattlesnake rims
more pics
toys; 08' sp.800
08'sp.400
05' yahama vmax
08' gmc Z71 short box
08'dodge avenger awd
98' yamaha srx

Actually alot of it is thanks to you Stendori. Wouldve had a much tougher time without your help. Thanks a ton.

I wish I had taken pictures. I might be able to remember the size tools I used so I can provide a tool list for those who wish to use the guide.

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2005 Polaris SP 500 H.O
L&R Cargo box and Bags
2500# Polaris Winch
Swisher plow/bucket

2005 Yamaha Wolverine 350
2006 Kawasaki Bayou 250
2005 Kawasaki KFX80

Install a Warn/Polaris Winch in 21 steps

Where were you last week...LOL

Well sound good to me, I also just finished putting my winch on my 800 yesterday also....Not bad at all, have to get out and use it now....

I can mount that winch in 19 steps!!!


j/k

Great info. Save it for later. It will come in handy. There are posts asking for winch help every other day.

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2007 X2
Vision 160 Wheels
Xtreme 3000 Winch
3 Headlight Mod.
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XR70R - "The Clown Bike"