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my polaris 2500 winch (off a 06Sportsman 500) freespooled on me this week. After looking at some winches online and the high cost(around $200) i decided to disassemble the winch i had and see what it looks like inside. Actually found a pictoral online of dissassembling a warn winch (i beleive its from this site) and although it's a little different, there really isnt that much to it. All the gears and teeth looked fine so after a more in depth inspection, i think the problem is that one end of the shaft is rounded over a bit when i think it should be hex, like the rest of the shaft. my mission was to now find out how to order the replacement part. i found a nice parts breakdown of both the polaris 2500 and 3500 winches along with a price list for each part. I called the local dealer with each of the part numbers i wanted to replace and although they didnt have them in stock Polaris did and there shipping them to me. I couldnt beleive how cheap the internal parts are. by cheap I mean $price. For the 4 parts i ordered it came to under $10.00. The shaft was $1.99 and by the way there was no plastic gears inside. for some reason I cant post the pictures, or the parts diagram (probly because im a newby to this forum) but it can be accessed at: http://www.polarisdealers.com/Dealer...01-2876494.pdf
The parts price list below refers to that diagram. I dont know if this will fix my winch but i'm fairly certain it will, and hopefully it will save me and some of you some money. And you may learn something at the same time. Theres nothing like fixing your own stuff.
Hopefully a moderator of this forum can place the parts diagram and price list in an appropriate place on this forum.
EK in CT
POLARIS 2500 LB. WINCH REPLACEMENT PARTS
Sold in single quantities unless otherwise noted.
Item Item Code M.S.R.P. POLARIS 2500 LB. WINCH REPLACEMENT PARTS ASM - Motor (#1) 2876774 $79.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Coupling - Brake, Rear (#5) 2876778 $1.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Lining - Brake (#6) 2876779 $2.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Coupling - Brake, Gear (#7) 2876780 $3.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Spool (#8) 2876781 $19.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Rod - Connecting (#9) Qty: 3 2876782 $2.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Spring - Freespool (#10) 2876783 $1.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Shaft - Hex (#11) 2876784 $1.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Knob - Freespool (#12) 2876785 $2.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Clip - Spring (#13) 2876786 $1.29 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Long (#14) Qty: 6 2876787 $1.29 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Casting - Winch, FS End (#15) 2876788 $44.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Slider Freespool (#16) 2876789 $1.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gear - Bull (#17) 2876790 $1.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 3 (#18) 2876791 $14.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 2 (#19) 2876792 $14.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bracket - Support (#20) Qty: 2 2876793 $6.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Fairlead - Roller (#21) 2876794 $12.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Nut - Nylock (#22) Qty: 2 2876795 $0.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Short (#23) Qty: 2 2876796 $0.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 1 (#24) 2876797 $9.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bushing - Spool (#25) Qty: 2 2876798 $1.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Plate - Winch Mount (#26) 2876799 $19.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bracket - Clamshell (#27) 2876800 $19.99 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Carriage (#28) Qty: 2 2876801 $1.49 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Nut - Nylock (#29) Qty: 2 2876802 $1.29 POLARIS 2500 LB. WINCH REPLACEMENT PARTS Clip - Retainer (#30) 2876803 $0.99
update to my winch repair.
I did receive a UPS box containing winch parts but only two of the 4 parts was ordered by the dealer correctly. The dealer who wont be mentioned (in Stafford, CT) ordered 2 parts from Polaris with the wrong part number, so i got parts i didn't need.
Anyways, luckily the two correctly ordered parts were the parts that fixed the winch. it was the
Slider Freespool (#16) Gear - Bull (#17)
So in the end my winch is operational again and it cost me $14.
Not much to a winch repair, as long as you can get the correct parts, so go for it before you just buy a new one.
Very nice. No plastic inside? Sounds like you have one of the polaris winches that were still produced by warn and you could probably find the parts from warn as well. Unlike the newer polaris winches that are made in china and are big pieces of crap. I have one of the warn made polaris winches and if for some reason it ever takes a dump and can't be repaired I'll buy a warn before purchasing one from polaris. I love polaris but it chaps my *** when they cheaped out on some parts like their winches among other things. What happened to quality and pride? OK I feel better now that I got to rant. LOL
Getting paid to play in a 6x6 monster machine, I love my job!
07 Stealth sp500 EFI. HO. LE.
07 H.D. Softail custom
01 Dodge Cummins Turbo-Diesel
Just so people have some idea of what's going on here with these winches and how cheaply it can be resolved - here are some pictures.
When my winch started freespooling I pulled it down and couldn't identify any issues with any components (everything looked in perfect condition). Even after reading this post I was still hesitant to accept that either the shaft or bull gear were worn as they looked cleanly machined and not scored/burred as I would've expected.
The photos below show how cleanly both components wear and give little to no indication they're compromised.
New bull gear on top.
Old bull gear on bottom showing 1/4-1/2" wear on internal spline
New shaft on right.
Old shaft on left showing 1/4-1/2" spline wear on the top (and some minor wear on the bottom but clearly you'd have a hard time knowing it wasn't machined like this from factory)
Personally I believe this a design fault stemming from too much movement in the planetary assembly on the engagement switch side of the winch and either poor shaft engagement or the shaft not engaging completely within the bull gear. Result is obviously the spline on the shaft gradually wearing out.
However it goes - if you're mechanically inclined it's really only a 30 minute $15 fix... which is not bad all things considered.
Hope this helps anyone experiencing the same issue (and provides some clarification to this thread).