Kolpin 26-3100 Manuel utilisateur

Polaris Sportsman Quick-Mount

2500lb. / 3500lb. Winch Kit

Product Instructions | Part No 26-3100 / 26-3110

Application Polaris Sports an, verify accessory fit ent at Kolpin.co .

Before You Begin Read these instructions and check to be sure all parts and tools are accounted for. Please retain

these installation instructions for future reference and parts ordering infor ation.

Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877- 56-5746.

18 13

This Kit includes

• Socket Set, Torx Bit

• Hex Key Set, Metric

• Torque Wrench

• Wire Cutter

Tools Required

• Safety Glasses

• Socket Set, Metric

• Screwdriver, Phillips

Item Qty Part Description

Part Number

26-3100 26-3110

1 1Handlebar Switch 2207175

25Cable Ties, Nylon -

34Hex Flange Screw, Zinc Plated, M8 x 1.25 - 25 LG -

41Mounting Bracket 25-3410

51Winch - Kolpin, 2500lb. / 3500lb. 25-9250R 25-9350R

61Hook, Winch Latch RPR0108

71Winch Cable, (Steel - 2500lb.) / (Synthetic - 3500lb.) 85062 85064

81Winch Connection Cable, Yellow 6 GA (368 ) -

91Winch Connection Cable, Blue 6 GA (267 ) -

10 1Power Connection Cable, Black 6 GA (510 ) -

11 1Power Connection Cable, Red 6 GA (530 ) -

12 1Contactor, Solenoid, 12V 85068

13 1Roller Fairlead 85069

14 1Rubber Winch Stopper (only included on 3500lb.) - 85080

15 4Button Screw, Zinc Plated, M8 x 1.25 - 20 LG -

16 2Socket Head Cap Screw, Zinc Plated, M6 x 1.0 - 10 LG 7517337

17 2Carriage Screw, Zinc Plated, M8 x 1.25 - 20 LG 7518479

18 2Hex Flange Locknut, Zinc Plated, M8 x 1.25 7547317

19 2Routing Clip Cable Tie, Nylon 7081496

20 1SPMN Winch Vehicle Harness -

22 1Instruction Guide (not shown) -

- - Service Free Spool Handle Knob (not included in kit) 85072

21 2Locknut, Zinc Plated, #10-32 7547341

Assembly Time Approxi ately 20 inutes

Sportsman XP Note If you need to install this kit on a Sports an XP 550/850/1000, see the instructions and photos

on page 8. The XP instructions shows the contactor location and wire routing for that configuration, and reasse ble the

contactor and wiring to atch those photos. Then follow the preceding instructions for final installation.

Important Your Kolpin Sports an Quick-Mount Winch Kit is exclusively designed for your vehicle. Please read the

installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For

your safety, and to ensure a satisfactory installation, perfor all installation steps correctly in the sequence shown.

SPORTSMAN 450/570 PREPARATION

1. Shift vehicle trans ission into “PARK”. Turn key

to “OFF” position and re ove fro vehicle.

2. Detach the rubber latch on both sides to open

front rack as shown. (See illustration 1-1).

3. Open the front rack and re ove rubber seal as

shown. Retain the seal for reinstallation. (See

illustration 1-2).

4. Re ove four screws holding front cover in place

as shown. Retain the screws for reinstallation.

(See illustration 1-3).

5. Lift the front cover upwards slowly to disengage

the tabs on cover fro the slots as shown. (See

illustration 1-4).

6. Disconnect black (negative) and red (positive)

cables fro battery.

7. Disconnect the black (negative) and red (positive)

cables fro the busbar as shown. (See

illustration 1-5).

8. Re ove the accessory front brush guard fro

vehicle (if equipped).

Ill. 1-1

Ill. 1-2

Rubber

Latch

Ill. 1-3

Rubber

seal

Front

Rack

Screws

Front

Cover

Ill. 1-4

Front

Cover

Slots

WARNING

ALWAYS disconnect black negative (-) cable

fro battery FIRST. Failure to do so will result

in high current electrical arc, and ay result in

battery explosion if tool touches grounded

fra e. Death or serious injury ay occur.

Ill. 1-5

Black

Cable

Red

Cable

Busbar

SPORTSMAN 450/570 PREPARATION

(continued)

9. Re ove lower front bu per cover fro vehicle by

re oving four bolts as shown. Retain bolts for use

during reinstallation. (See illustration 1-6).

10. Re ove winch cover fro the lower front bu per

cover. If you plan to use a plow, re ove winch

cover fro the lower front bu per cover and do

not reinstall. If you do not plan to use a plow on

your vehicle, cut out the center section as shown

and reinstall winch cover on the lower front

bu per cover if you desire, but it is not required.

(See illustrations 1-7 and 1-8).

NOTE: Before installing the winch kit, add or replace the proper

fluid to your front gearcase as required per your vehicles service

manual as this process will be difficult to do after the winch is installed.

SPORTSMAN 450/570 WINCH INSTALLATION

NOTE: See the Electrical Connections Reference Guide section

of the instruction manual for detailed photos of each part and their

respective connections.

11. Check and confir wire routing and connections are as shown and ake

necessary adjust ent before oving to next installation steps. (See

illustration 1-9).

12. On vehicle, locate white contactor connector as shown, clip plastic cable

tie, re ove the cap. (See illustration 1-10).

Ill. 1-6

Ill. 1-7

Front

Lower

Bu per

Cover

Ill. 1-8

Winch

Cover

OEM

bolts

Ill. 1-9

Red

Cable

Black

Cable

Tri ed

Winch

Cover

Use this routing clip. Close two

wires and tri excess tie.

This cable tie will

not be used and can

be re oved fro

this clip.

Ill. 1-10

Cable

Tie

Connector

Cap

SPORTSMAN 450/570 WINCH INSTALLATION (continued)

13. Locate the red and black wires on winch asse bly. If they are

secured to blue cable with a plastic tie, cut the tie to allow the

wires to be routed properly. (See illustration 1-11).

14. Re ove the accessory front brush guard fro vehicle (if

equipped).

15. Install winch asse bly onto the radiator ount with the

four M8 hex flange screws (ite #3). Check that all

wires are free to ove and not pinched between the

vehicle chassis and the winch asse bly. Access is

easier by inserting the black and red power cables first

into window above front gearcase as shown, then

position winch otor side into bu per fra e first

followed by lifting clutch free spool handle end last.

(See illustrations 1-12, 1-13 and 1-14).

16. Tighten the four M8 screws (ite #3) to torque

specification.

Ill. 1-11

Ill. 1-12

Ill. 1-13

Bu per

Fra e

Clutch

Free

Spool

Winch

Motor

side

Re ove

packaging

tie

Front

Gearcase

Black

Cable

Red

Cable

Ill. 1-14

8MM FASTENER TORQUE

17 ft. lbs. (23 N )

SPORTSMAN 450/570 WINCH

INSTALLATION (continued)

17. Route red positive (ite #11) and black

negative (ite #10) power connection

cables directly underneath the radiator

then up behind it to reach the three

ter inal bus bar as shown. Using two of

the plastic cable ties (ite #2), loosely

secure the red and black power cables to

the fra e and existing wiring. (See

illustration 1-15).

Note, do not connect

the winch cables to the busbar at this

time.

18.

For 2015 & Newer Vehicles:

Locate the

white connector on the contactor and

connect it to the corresponding connector

on the vehicle harness as shown. (See

illustration 1-16).

19.

For 2014 & Older Vehicles:

Route the

supplied SPMN winch vehicle harness

(ite #20) fro the head light pod down

to winch, using sa e path behind radiator

as the black and red winch power cables.

Connect the white harness connector to

the winch contactor connector. Route the

red end (12V accessory power) of

harness to busbar area and connect to

orange wire on vehicle ain harness as

shown. Secure winch harness to vehicle

using cable ties (ite #2). (See illustration

1-17).

20. Now connect the vehicle battery red and

black wires to the busbar ter inals and fasten using existing nut.

Then connect the winch power cables, red and black, (ite s #11

and #10) to the busbar ter inal and fasten using supplied nut

(ite #21) as shown. (See illustration 1-18).

Ill. 1-15

Ill. 1-16

Vehicle

Connector

Contactor

Connector

Overhead view

Ill. 1-18

Ill. 1-17

Orange

Wire

SPORTSMAN 450/570 HANDLEBAR SWITCH

INSTALLATION

21. Install the handlebar switch (ite #1) using the

supplied screws onto the handlebar as shown.

Torque screws to the specification listed, being

careful not to overtighten. (See illustration 1-19).

22.

For 2015 & Newer Vehicles:

Re ove cap fro

vehicle switch connector. Then connect handlebar

switch connector to the vehicle ain wire harness

as shown. (See illustration 1-20).

23.

For 2014 & Older Vehicles:

Route the supplied

SPMN winch vehicle harness (ite #20) up

through the headlight pod towards left-hand grip

area. Use cable tie (ite #2) to secure switch

connector end to handlebar as shown. Then

connect handlebar switch connector to the winch

harness as shown (See illustration 1-20).

SPORTSMAN 450/570 FINAL INSPECTION

24. Confir that all wiring is correct.

25. Confir that there are no exposed wires or ter inals.

26. All loose wires need to be wrapped tight, and secured away fro

oving parts and heat sources.

SPORTSMAN 450/570 REINSTALLATION

27. Reinstall the lower front bu per cover. If you plan to use a plow, do

not reinstall winch cover. (See illustration 1-21).

28. If you do not plan to use a plow, reinstall winch cover. (See

illustration 1-22).

29. Reinstall accessory brush guard (if equipped).

30. Reconnect battery red (positive) and black (negative) cables to

battery ter inals at this ti e.

31. Reinstall the front cover (under front rack) using retained screws.

32. Close front rack and secure in place with rubber latches.

33. With vehicle key in the ON position, check winch for proper

operation.

Ill. 1-19

Supplied

Screws

SWITCH SCREW FASTENER

TORQUE

2 ft. lbs. (2.7 N )

Ill. 1-20

Vehicle

Switch

Connector

Ill. 1-21

Ill. 1-22

Front

Bu per

Cover

Front

Bu per

Cover

Winch Cover

SPORTSMAN XP 550/850/1000

PREPARATION

1. Shift vehicle trans ission into “PARK”. Turn key

to “OFF” position and re ove fro vehicle.

2. Detach the rubber latch on both sides to open

front rack.

3. Rotate/open two latches and re ove storage tray

fro vehicle as shown. (See illustration 1-24).

4. Disconnect black (negative) and red (positive)

cables fro battery as shown. (See illustration

1-25).

5. Re ove the accessory front brush guard fro

vehicle (if equipped).

6. Re ove the lower front bu per cover by

re oving four bolts. Retain bolts for use during

reinstallation as shown. (See illustration 1-26).

7. Re ove the winch cover fro the front lower

bu per cover by re oving two push pin rivets.

The winch cover and push pin rivets will not be

needed while the winch is installed on the vehicle

as shown. (See illustration 1-27).

Note, your

vehicle’s factory tool kit contains a pliers

specifically designed for the removal of push

pin rivets.

Ill. 1-24

Black

Cable

Storage

Tray

Screws

Red

Cable

WARNING

ALWAYS disconnect black negative (-) cable

fro battery FIRST. Failure to do so will result

in high current electrical arc, and ay result in

battery explosion if tool touches grounded

fra e. Death or serious injury ay occur.

Winch

Cover

Plastic

Push

Rivet

Bu per

Cover

Ill. 1-25

Ill. 1-26

Ill. 1-27

Bu per

Cover

SPORTSMAN XP 550/850/1000 PREPARATION

(continued)

NOTE: Before installing the winch kit, add or

replace the proper fluid to your front gearcase as

required per your vehicles service manual as this

process will be difficult to do after the winch is

installed.

SPORTSMAN XP 550/850/1000 WINCH

INSTALLATION

NOTE: See the Electrical Connections

Reference Guide section of the instruction manual for

detailed photos of each part and their respective

connections.

8. Locate the red and black wires on winch

asse bly. If they are secured to blue cable with

a plastic tie, cut the tie to allow the wires to be

routed properly. (See illustration 1-11).

9. The 26-3100 / 26-3110 winch asse bly contains

the sa e parts to work on Sports an 450/570

and Sports an XP 550/850/1000. The winch

pre-asse bly will need the contactor to be

relocated to fit on Sports an XP 550/850/1000

vehicles. First loosen the red (ite #11), black

(ite #10), blue (ite #9) and yellow (ite #8)

connection cables fro winch (ite #5) and

contactor (ite #12). Then loosen and re ove

the M6 socket head cap screws (ite #16) that

secure contactor to ounting

bracket (ite #4) as shown. (See

illustration 1-28).

10. Relocate the contactor to the back

tab of the ounting bracket as

shown. Secure the contactor to

bracket using the two M6 socket

head cap screws. (See

illustrations 1-29 and 1-30).

11. Torque to M6 specification.

Ill. 1-28

Screws

re oved

Contactor

ready for

relocation

Ill. 1-29

Ill. 1-30

Relocated

Contactor

to back tab

6MM FASTENER TORQUE

7 ft. lbs. (9.5 N )

SPORTSMAN XP

550/850/1000 WINCH

INSTALLATION

(continued)

12. Check and confir wire

routing and connections

are as shown and ake

necessary adjust ents

before oving to next

installation steps. (See

illustrations 1-31 and

1-32).

13. Install winch asse bly

onto the radiator ount

with the four M8 hex

flange screws (ite #3).

Check that all wires are free to ove and not

pinched between the vehicle chassis and the winch

asse bly. Access is easier by inserting the black

and red power cables first into window above front

gearcase as, then position winch asse bly into

vehicle chassis as shown. (See illustrations 1-33

and 1-34).

14. Tighten the four M8 screws (ite #3) to torque

specification.

Ill. 1-31

Red

Cable

Black

Cable

Use this routing clip. Close two

wires and tri excess tie.

This cable tie

will not be

used and can

be re oved

fro this clip.

Ill. 1-33

Ill. 1-32

8MM FASTENER TORQUE

17 ft. lbs. (23 N )

Ill. 1-34

Ce manuel convient aux modèles suivants

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