For your safety, always follow these guidelines when winching a vehicle free:. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper, or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch. Extensive winching will run down the battery on the winching vehicle.
Let the winching vehicle's engine run while operating the winch to prevent the battery from running low if winching for long periods. After winching is complete — especially if winching at an angle — it may be necessary to re-distribute the winch cable across the winch drum.
You will need an assistant to perform this task. Failure to relieve rope tension prior to changing gears may result in winch failure, resulting in serious personal injury or death. Your winch is equipped with two or three different gear settings. On winches with two settings they are Engaged or Disengaged. When in neutral, "N" will be visible in the cutout window on the shift knob on the left-hand side of the winch.
Relieve all tension from the rope and then rotate the gear select knob counter-clockwise until "L" is visible in the shift knob cutout window. Relieve all tension from the rope and then rotate the gear select knob clockwise until "H" is visible in the shift knob cutout window. If difficulty is encountered while shifting into HIGH, pull the winch rope slightly by hand to help align the gears.
It is NOT intended for rope retraction while under load. Using high gear while under load will result in reduced winch life. As a result, using this feature will significantly reduce the time needed to recover the rope after use. Polaris recommends always returning the gear selector to LOW after rapid recovery to prevent inadvertent future operation in HIGH gear. Winch Cable Care For your safety, always replace Polaris winch parts including the cable with genuine Polaris replacement parts available at your authorized Polaris Dealer.
Synthetic winch cables are 50 feet long. Warning: Use of worn or damaged cable could lead to sudden failure and severe injury. Inspect your winch before every use. Check for worn or loose parts including mounting hardware.
Never use the winch if any part needs repair or replacement. Inspect your winch cable before every use. Check for worn or kinked winch cable. A kinked winch cable made of wire rope is shown below. Even after being "straightened out" this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.
A kinked winch cable made of wire rope that has been "straightened out" is shown below. Even though it may look usable, the cable has been permanently and severely damaged.
It can no longer transmit the load that it could prior to kinking. A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed shown below. Also replace the winch cable if there are fused or melted fibers. Such an area of synthetic rope will be stiff and appear smooth or glazed.
Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause severe injury or death to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. Never attempt to "jerk" a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object.
This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable. Warning: Severe injury or death can result from a broken winch cable. This puts extra load on the winch, winch cable, and generates excessive heat from the motor.
This is a form of shock loading. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading to the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle.
This can cause instability of the vehicle and possibly lead to an accident. Remote control switch Test winch operation with or cord is damaged. Replace remote control if defective. Battery ground wire Connect ground wire connected to vehicles frame. Motor battery Repair insulator or replace connections have been motor improperly tightened, and turned to pinch insulation from motor body d.
Electrical ground is not Install a ground wire to the sufficient. Ground wire was not motor housing, and attach to the installed, or the battery ground negative terminal of the battery. Page 30 The following Parts breakdown and parts lists are for current winch models. Print page 1 Print document 45 pages. Rename the bookmark. Delete bookmark? Cancel Delete. Delete from my manuals? Sign In OR. Don't have an account? Sign up!
This is a straight forward fix for. Does anyone have this, for a lb warn winch. It has the old Here is the installation manual from Warn. It's a PDF file. Congratulations on your purchase of a KFI winch.
You can also find other images like wiring diagram, parts diagram, replacement parts, electrical diagram, repair manuals, engine diagram, engine scheme, wiring harness, fuse box, vacuum diagram, timing belt, timing chain, brakes diagram.
Warn's first VR-series winches was a toe-dipping in the water. They've clearly been successful, because they just keep making them. The styling of these earlier winches wasn't too fancy - the control packs were just starting to get some styling to make them look tactical. Each of these winches used the old-style tie rods between the motor and gearbox to tie the winch together. We don't have a preference for either, but later winches switched to a tie plate.
There were five winches in the VR line: click the links to see stats, manuals, and parts lists for each. This was the time of the beginning of synthetic winch line offerings, so Warn only offered the lighter-weight synthetic version for the 8, and 10, lb winches. This is indicated by the "-S" on the end of the model number.
Probably the most noticeable change is the new, sleek, tactical appearance. Instead of the tie rods that hold the cases together, this winch uses a tie plate that the control box rests on. One big change is the fairleads: where the 1st Gens used a steel roller fairlead or a polished aluminum hawse, the 2nd Gens all came with a cast steel hawse.
Cast steel is fine for both steel winch line and synthetic, but the hawse will rust with steel lines once the powdercoat wears off. This fairlead definitely felt like a step back from the more traditional steel roller and aluminum hawse of the earlier version. While the 1st Gens came with solenoid control packs, these used a waterproof Albright contactor pack. This was exciting because contactors have developed a reputation for being more reliable than solenoids.
Plus, while it's always been easy to soak winch solenoids - they aren't sealed AT ALL - this control pack is completely waterproof. This generation of winches was probably the first budget winch to offer an Albright contactor pack. Performance-wise, this generation performs exactly the same as the 1st Generation VR winch. The gear ratio, pull-by-layer data, amp draw, and line speed are all exactly the same. There were six winches in the 2nd Gen VR line: click the links to see stats, manuals, and parts lists for each.
This generation of VR winches also added a synthetic version for the lb winch. Like the 1st Gen, a synthetic version is indicated with a "-S". We've included the graphs here, but note that they're exactly the same as the last set you looked at. There are some very interesting and significant changes with the 3rd generation of Warn's VR line. This generation has a slightly updated appearance - if the 2nd Gen VRs were sleek and tactical, this generation of winches is even moreso.
Warn not only kept the fancy waterproof Albright contactor pack, they've actually upgraded the controller to be wired and wireless. This can actually mean various things, but we'd expect that you can dunk this winch on a river crossing and not have water enter the gearbox or motor.
This is not the case with other Warn winches like the M8 , M10, M12 , etc although those are high-quality winches assembled in the US. There are six winches in the VR EVO line: click the links to see stats, manuals, and parts lists for each. Like the 2nd Gens, this generation of VR winches has three steel cable winches and three synthetic line. Without a doubt, one of the most interesting things about the VR EVO line is that the motor and gearbox are different than the old versions.
The biggest differences are that the amp draw is lower for these winches across the board sometimes very significantly and the pulling power is decreased with each additional wrap of cable on the drum.
We're going to directly compare each generation of the VR winch line across weight classes below. The old VR winches are markedly different from the newer ones. Let's take a look at the lb winches first. First, note that the 1st and 2nd Gen winches have exactly the same performance characteristics, so they precisely overlap in this graph.
The VR EVO lb winches are slower with no load on the winch line, but are now almost twice as fast as previous VR generations at full load. Our thought is that at lower loads, you won't notice too much difference between the old and the new, but at full load, it'll be pretty different.
Amp draw is also drastically reduced with the new EVOs. At full load, you can expect to be pulling around amps less!
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