Can.anyone guide.me on removing the winch on my sportsman 500 4x4. The cable got wrapped around the spool. So I can take the winch apart to fix it.
Thanks jacob
Thanks jacob
jdantz3
Hello & Welcome :wave:
Your best bet would be to pull the front bumper plastics, and undo the mounting bolts from the mounting plate. Some times it works to have someone else run the in/out switch, while you tug on the cable hook or vise-versa. Have to tried to switch the winch spool to free wheel and give it a pull by hand?
Note: After I think about it.... Technically the cable is suppose to we wrapped around the winch, but I know what you mean
Your best bet would be to pull the front bumper plastics, and undo the mounting bolts from the mounting plate. Some times it works to have someone else run the in/out switch, while you tug on the cable hook or vise-versa. Have to tried to switch the winch spool to free wheel and give it a pull by hand?
Note: After I think about it.... Technically the cable is suppose to we wrapped around the winch, but I know what you mean
Kind of start at the bottom and work your way to the top.
How to install a Polaris/Warn winch on a 2005 Sportsman 500
1. At the front of the ATV, reach in and pull off POLARIS plastic front cover. (should snap right off)
2.Remove 4 bolts that secure the front assembly (two are visible after removal of plastic cover removed in step 1)
3. Remove headlight connectors (2) and remove entire front bumper/grill assembly - set aside.
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.
5. At this point you can reattach the front assembly(using the 4 bolts you removed) and headlight connectors.
6. Open front cargo box and remove access panel over radiator, then remove plastic access panel under top headlamp.
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)
8. Mount the thumb switch to the handlebars by removing the 2 hex bolts that hold on the headlight switch. Place the spacers between the thumb switch mount and the headlight switch mount and use the longer bolts that should be included to secure.
9. Remove the single headlamp cover. (3 Phillips head screws) and run the wires from the thumb switch down the bar and into the headlight area and down to where you ran the two winch cables. Re-attach headlamp cover.
10. Remove the seat and both black side covers (it isn't necessary to remove the side covers but they attach easy and it makes it easier to get to everything.)
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.
12. Fish the two winch cables and the wire with the pod on it from the thumb switch 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)
13. Attach the Winch Solenoid to the plate using bolts included with the winch.
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.
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 .
16. Attach pod from thumb switch to male end from solenoid. Pull rubber solenoid cover over the solenoid (covering the leads)
17. Re-attach cable attached 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)
18. Back up top - Find the single spade ended cable coming from the thumb switch 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.
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.
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.)
Replace both side covers and seat. - Start up ATV and give her a whirl!!
How to install a Polaris/Warn winch on a 2005 Sportsman 500
1. At the front of the ATV, reach in and pull off POLARIS plastic front cover. (should snap right off)
2.Remove 4 bolts that secure the front assembly (two are visible after removal of plastic cover removed in step 1)
3. Remove headlight connectors (2) and remove entire front bumper/grill assembly - set aside.
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.
5. At this point you can reattach the front assembly(using the 4 bolts you removed) and headlight connectors.
6. Open front cargo box and remove access panel over radiator, then remove plastic access panel under top headlamp.
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)
8. Mount the thumb switch to the handlebars by removing the 2 hex bolts that hold on the headlight switch. Place the spacers between the thumb switch mount and the headlight switch mount and use the longer bolts that should be included to secure.
9. Remove the single headlamp cover. (3 Phillips head screws) and run the wires from the thumb switch down the bar and into the headlight area and down to where you ran the two winch cables. Re-attach headlamp cover.
10. Remove the seat and both black side covers (it isn't necessary to remove the side covers but they attach easy and it makes it easier to get to everything.)
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.
12. Fish the two winch cables and the wire with the pod on it from the thumb switch 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)
13. Attach the Winch Solenoid to the plate using bolts included with the winch.
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.
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 .
16. Attach pod from thumb switch to male end from solenoid. Pull rubber solenoid cover over the solenoid (covering the leads)
17. Re-attach cable attached 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)
18. Back up top - Find the single spade ended cable coming from the thumb switch 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.
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.
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.)
Replace both side covers and seat. - Start up ATV and give her a whirl!!
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