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Old 05-28-2013, 11:24 AM
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Superwinch install question

Hi, new member here with a 2013 sportsman 500. I bought a superwinch lt2500 and installed it but have a question regarding their circut breaker. Its two 50amp breakers on a buss bar which is not insulated at all. instructions say to wrap in electrical tape. I've installed many winches from warn and others and this is the first one with a circut breaker.

Are these winches different than others thus requiring a breaker? It looks like any other atv winch from china I've seen or installed and has similar amp draw.

Any thoughts on how to insulate it to prevent short circuiting it other than the proposed electrical tape idea which is a piss poor method to say the least.

Thanks Anthony
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Old 05-28-2013, 11:51 AM
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Radio Shack sells a large diameter shrink tube (something like an inch diameter or so) like the stuff used to hold thumb warmers on the throttle levers. Would something like that be large enough to slip over the buss bar?
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Old 05-28-2013, 11:57 AM
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Not sure if I can find a piece that wide but ill give it a try. I see your in post falls. I'm in Wallace and just bought this machine from cda polaris. Anyway superwinch absolutely should have supplied some method of insulating this unit. I cannot believe it hasn't caused fires followed by lawsuits. I'm not joking, it's two breakers mounted in parallel to two pieces of bare aluminum.
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Old 05-28-2013, 12:10 PM
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Can't say that I've seen the Superwinch installation like you describe, but I know the install of my $70 Master Lock (from Wal-Mart) winch would REALLY make you laugh! (Visualize a wired hand-held remote with no contactor and all current passing through the cables, and no lock on the remote to prevent it from being accidentally actuated when stuffed in a compartment.) I'll replace it with a real winch someday.

Got my '09 from CdA Polaris too. Small world, eh? It's a pleasure to see another Idahoan on the forum! - MarkC
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Old 05-28-2013, 12:12 PM
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Breaker vs. Fuse a user friendly and good idea..... no insulation on bars, would be a poor idea!

How about liquid electrical tape or plasti dip (basically same thing)??? I would think this would prevent your concerns of "arching and sparking"!?!?!
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2012 POLARIS SPORTSMAN 800 EFI (INDY RED)
Mods: Polaris 2500HD Winch - Glacier 3 60" Plow System - Front & Rear Rack Extensions - Front & Rear Bumper/Brush Gaurds - Low Profile Windshield - Warning Debadge - 3 Way Head Light (Relay) - Coleman Rear View Mirror - Kolpin KXP Rhino Double Gun Rack - Madd Dog Chainsaw Holder - Kolpin Rear Seat/Storage Box - Kolpin Fuel Pack Jr - 26" ITP Mud Lite Tires - Front & Rear High Lifter HD Springs

2005 POLARIS SPORTSMAN 400 (SONIC BLUE)
Mods: Warn 2500 Winch - Polaris Hand Guards - WES Ind. Rear Seat/Storage Box - Shift Interlock Delete - Coleman Rear View Mirror - Front & Rear Bumper/Brush Gaurds - 25" Kenda K590 Tires - PVC Spring Spacers

Son's: 2012 TaoTao 125D (BLUE/BLACK)
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Old 05-28-2013, 01:06 PM
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Re: Superwinch install question

I installed a winch on my quad a couple months ago and ran into the same issue. I think most people mount the fuse/breaker bar directly to the battery. Didn't work for my battery so I got an extesion cord coupler cover and modified it so it would fit inside to insulate it from the frame.

Sent from my ADR6350 using Tapatalk 2
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Old 05-28-2013, 01:39 PM
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^^^ That's good thinking too!!
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2012 POLARIS SPORTSMAN 800 EFI (INDY RED)
Mods: Polaris 2500HD Winch - Glacier 3 60" Plow System - Front & Rear Rack Extensions - Front & Rear Bumper/Brush Gaurds - Low Profile Windshield - Warning Debadge - 3 Way Head Light (Relay) - Coleman Rear View Mirror - Kolpin KXP Rhino Double Gun Rack - Madd Dog Chainsaw Holder - Kolpin Rear Seat/Storage Box - Kolpin Fuel Pack Jr - 26" ITP Mud Lite Tires - Front & Rear High Lifter HD Springs

2005 POLARIS SPORTSMAN 400 (SONIC BLUE)
Mods: Warn 2500 Winch - Polaris Hand Guards - WES Ind. Rear Seat/Storage Box - Shift Interlock Delete - Coleman Rear View Mirror - Front & Rear Bumper/Brush Gaurds - 25" Kenda K590 Tires - PVC Spring Spacers

Son's: 2012 TaoTao 125D (BLUE/BLACK)
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Old 05-28-2013, 01:59 PM
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where would I find an extension coupler cover? Honestly have not seen one. Anthony
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Old 05-28-2013, 02:59 PM
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Should be able to find them at any hardware store. I had to modify mine by cutting out ribs inside to get it to fit but it worked as was cheap. The bigger the better.

Cord Connector-Orange at Menards

Another link to the same item w/ more pics
Water-Tight Locking Extension Cord Connector
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Old 05-28-2013, 03:29 PM
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I used a pair of insulated power distribution studs in place of the cable bolts.
Similar to this one.
Amazon.com: Insulated Distribution Stud, 3/8 Inch, Red: Sports & Outdoors Amazon.com: Insulated Distribution Stud, 3/8 Inch, Red: Sports & Outdoors

The insulated bases bolt to the side of the battery box. I hosed the entire assembly down with Wurth HHS 2000 after installing the cables... Fluid Film or any other spray di-electric grease will work the same.
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