how to install a warn rt30 winch on a 2011 polaris sportsmen 500 ho

sinners · #1 (**permalink**) 05-21-2011, 07:11 PM

I just bought a new polaris 500 ho 2011. I got a warn 25xt winch with a kfi mount. I've been threw this forum and found some awesome install posts. First off, the screw on the kfi mount snapped while i was hand tightening it to the frame

. Will call KFI monday to get it resolved.
On to the main issue. I installed the winch and ran the wires. Upgraded the blue and yellow to 6 gauge wires. Used the preinstalled battery wire(blk and red) and attached the back black plug onto the batter. I started up the atv and pushed the reel in and out. I can hear the motor inside the winch moving but the spool is doing nothing. I checked to see if it was rubbing or catching on something but i can free spool it no problem.
any ideas? will call warn on monday.
thanks

Nwcid · #2 (**permalink**) 05-21-2011, 07:34 PM

Did you engage the clutch on the winch so that it will power in and out? If you are in "free spool" it will not power in or out. Very detailed instructions in your book, I know just put one on yesterday.

sinners · #3 (**permalink**) 05-21-2011, 07:59 PM

I did turn the red knob on the winch. I went out right after i posted and checked the voltage and did another scan and test. The cable will pull out when not in free spool. Also, i finally got the cable to retract a few inches and then it stopped and i hear noise from the winch. I'm guessing i got a bad one with a bad gear set up.

cwlongshot · #4 (**permalink**) 05-22-2011, 02:38 AM

Mornin and sorry to read of the winch problems!

I think you have an internal problem with the winch. Either the clutch or the gears as you suspect. Either way, I would say your correct with turning it over to WARN...

CW

Nwcid · #5 (**permalink**) 05-22-2011, 07:05 AM

If it will free spool when in the "engaged" position then you have a problem where you need to call Warn.

sinners · #6 (**permalink**) 05-25-2011, 02:48 PM

Just an update. What a nightmare this has been. The KFI mount people were horrible to deal with. Ended up forcing the broken bolt out and buying a new set of four from my local lowes. Warn winch apparently had misaligned gears and needed to be ran for a few minutes to line up again(?) i said whatever as long as it works.
I also ordered a polaris oem front and rear brush guard. Front brush guard = another snapped bolt. apparently my out of shape hand tightening is too much for these great bolts. Rear brush guard, tried to be very gentle and not tighten them really at all and now they won't even tighten. Stripped just going into the frame. I may try and call polaris but will probably end up getting all new bolts and adding a nut to the back side of the rear brush guard.

also, the warn contactor box, broken bolt... i was finger tightening it. I will say that warn has been easy to deal with so far. My local store where i bought the damn atv is dead to me. Apparently once they have your money and realize you're doing the install and maintenance yourself they didn't care about me anymore. It is the ride now branch in AZ. Also, all they sell is polaris atvs... they ordered me the wrong mount because they didn't know the 2011's took a different one... RIGHT!?

sigh

antoniodef · #7 (**permalink**) 05-25-2011, 04:35 PM

I hear you on the wrong mount. Dealer by me ordered me the wrong winch. I told them the 11's were diffeent, but they convinced me they weren't. That's crazy about all the bolts. I did snap one installing the plow plate to my frame though. Didn't strip, but popped the head off. Not sure what the bolts were made of, but they felt as heavy as air. Bought two new ones after a used an EZ out.

Good luck getting it all sorted.

vtelvr · #8 (**permalink**) 06-02-2011, 11:11 AM

Sinners, a word of advice on the bumpers: I installed both polaris items, but I used better hardware than what they supplied. I took the oem bolts to Home depot and was able to match them to GOOD hardware, and installed it that way. I bolted the rear brushguard on with bolts and nuts. I tried the "tap the frame" crap with their chinese bolts, and that was a joke. I ended up taking the seat off, then taking out the black pins that secure the rear fenders. After doing that, you can slip your utility box towards the front of the atv. Once you have done that, you can get to the back side of the "c" channel frame to get nuts on the bolts. Feel free to PM me if you have any other questions.

Oh, and yeah, the dealership almost laughs at you once you come back in after the initial purchase. I have decided I will not go back unless there is absolutely no way around it.