KOLPIN OUTDOORS 25-9605 Polaris Ranger 6000 lb Synthetic Rope Winch Instruction Manual

6000 lb UTV WINCH KIT
P/Ns: 25-9605
OWNER’S / OPERATING INSTRUCTIONS / SPARE PARTS

25-9605 Polaris Ranger 6000 lb Synthetic Rope Winch

Application
WINCH MOUNT NO. 25-XXXX, OEM VEHICLE WINCH MOUNTS
Before you begin, please read these instructions and check to be sure all parts and tools are accounted for. The following instructions contain details required to operate, install and service the contents of this kit. Save these instructions. Important safety instructions are included in this manual.

INTRODUCTION

Congratulations on your purchase of a Kolpin winch! The Kolpin winch works great for vehicle recovery and plow lift applications. With proper use and maintenance, this winch will bring many years of satisfying service.
Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice.
Record the part numbers, date of purchase and place of purchase for future reference. Please have this information available when ordering parts and when making technical or warranty inquiries.
Kolpin Outdoors Support
1-877-9 56 -5746
Part Number
Date of Purchase
Purchase Location
GUIDEBOOK CONVENTIONS
This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a signal word to alert you to potential hazards in operating and owning power equipment. Follow all safety messages to avoid or reduce the risk of serious injury or death. Each message has a specific purpose. PLEASE WORK SAFELY!
WARNING
WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTE
If you have questions regarding your winch, we can help. Please call our help line at 1-877-956-5746.
CONTROLS AND FEATURES
Read this owner’s manual before operating your winch. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Some features may not exist on all models, but can be ordered as options, please contact technical services at 1-877-956-5746.

1. Motor: 12V DC motor provides power to the planetary gear mechanism.
2. Braking System: Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the winch cable.
3. Winch Drum: The winch drum is the cylinder on which the wire rope is stored. It can feed or wind the rope depending on the remote winch switch signal.
4. Planetary Gear System: The reduction gears convert the winch motor power into extreme pulling forces. This system allows high torque while maintaining compact size and light weight.
5. Free Spooling Clutch: The clutch allows the operator to manually disengage “Out” the spooling drum from the gear train, free spool. Engaging the clutch “In” locks the winch into the gear system.
6. Fairlead Mounting Bracket: Allows roller fairlead to be mounted with winch to vehicle surface.
7. Roller Fairlead: When using the winch at an angle, the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper.
8. Rubber Winch Stop: Increases life of cables, ropes and fairleads. Quiets hook rattling noise.
9.  Rope: Galvanized steel aircraft cable or synthetic rope designed specifically for winch load capacities.
10. Winch Connection Cables: Used to connect the contactor to the winch motor.
11. Battery Connection Cables: Used to connect the battery to the contactor.
12. Clevis Hook: Provides a means for connecting the looped ends of cables to an anchor.
13. Hand Saver Strap: Used to safely assist cable feed into winch.
14. Contactor/solenoid: Power from the vehicle battery flows through the weather sealed contactor/solenoid switch before being directed to the winch motor. (15) Dash Panel Rocker Switch: Rocker switch with dash panel mount for powering the rope in or out of your winch drum.
15. Corded Remote Switch: Corded remote switch allows the operator to stand clear during the winching process.
16. ) Dash Switch Wiring Harness: Allows the dash switch to be electrically connected to winch contactor.
17. 3-Way Splitter Wiring Harness: Allows the dash switch accessory power pigtail wire connector to be electrically connected to corded remote accessory power pigtail wire connector and vehicle accessory power wire connection.

ASSEMBLY

The winch kit comes mostly assembled from the factory. Some pre-assembly of the kit is required for installation into vehicles.
BEFORE YOU BEGIN:

• Your Kolpin accessory is designed for a universe fit for most vehicles.
• Please read and understand all instructions.
• Verify all parts and tools are accounted for.
• To ensure a satisfactory installation, follow all steps correctly and in the sequence described.
• To facilitate installation, make sure that your vehicle is clean and free of debris.
• All directions referring to right and left are when the rider is sitting on the machine.

TOOLS REQUIRED:

• Basic metric wrench set
• Basic metric socket set
• Pliers
• Philips screwdriver

MOUNTING THE WINCH

• If using a winch mounting kit, refer to the kit’s manual for specific installation instructions. See Kolpin.com for a full assortment of custom winch mounts for UTVs.

• Mount the winch to the mount plate (not included) as shown below.
  Rotate the lock knob to the free spool position and feed the winch cable through the rollers of the roller fairlead.

• Mount the roller fairlead plate and attach the hook clevis and nylon pull strap. Rotate the lock knob back to the lock position.

WARNING
ALWAYS use supplied hook strap.
NOTICE
ALWAYS ensure that the 3 major sections (motor, drum, gear housing) are properly aligned if utilizing a mounting plate. Proper alignment of the winch will allow for even distribution of the full rated load.

Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877-956-5746.
MOUNTING THE DASH PANEL SWITCH
VEHICLE PREPARATION:

1. Shift vehicle transmission into “PARK”. Turn ignition key to “OFF” position and remove from vehicle ignition.

2. Disconnect black negative (-) cable from battery first, then disconnect red positive (+) cable from battery.
   WARNING
   ALWAYS disconnect black negative ( -) cable from battery FIRST. Failure to do so will result in high current electrical arc, and may result in battery explosion if tool touches grounded frame. Death or serious injury may occur. UTV DASH MOUNT SWITCH INSTALLATION:
   NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photo of each part and their respective connections.

3. Install dash mount switch (item #4) to desired location on your dash. Check to see if your vehicle has marked rectangular predefined switch location and trim area out. If not, use the cut-out dimensions shown below to cut-out the switch location in your desired location. (See illustrations 1-1 and 1-2). Note, illustration 1-1 is not to scale. Measure and mark cutout using the dimensions provided.

4. Connect the dash mount switch (item #4) to the provided vehicle Dash Switch Harness. Connect green wire to the “Out” pin, red wire to the middle pin and black wire to the “In” pin as shown. (See illustration 1-3).

5. Insert the dash switch harness and switch assembly thru the panel hole as shown. The switch will clip into the dash panel. (See illustration 1-4).

6. Connect the white connector of harness (item #4) to the winch contactor harness.

7. Connect the red wire of harness (item #4) to the vehicle keyed power accessory.

8. Confirm that all wiring is correct.

9. Confirm that there are no exposed wires or terminals.

10. All loose wires need to be wrapped tight, and secured away from moving parts and heat sources. SWITCH OPERATION:
    When properly installed, the dash rocker switch allows you to operate the winch while seated in the vehicle. Proper switch operation is shown. (See illustration 1-5). MOUNTING THE CORDED REMOTE SWITCH
    (optional on some models)
    • Determine the mounting location for the remote socket. Exact position may vary depending on vehicle. Drill three holes and install to vehicle dash panel or body panel.
    • Route the wire harness to where the contactor/solenoid will be mounted. Secure the socket’s cable with the supplied cable ties.
    • Using the provided wire splice, splice the end of the red wire to a key controlled, accessory circuit (power-point) of the UTV or use the provided wire eyelet terminal connector to connect to a vehicle terminal strip post. The wire should only have power when the key is in the “ON” position.
    • NOTE: If installing both switches (dash panel switch and corded remote), both red wires must be connected together with the provided plug connectors or spliced to a key-controlled accessory circuit of the UTV as described in the above step.
    NOTICE
    ALWAYS make sure to splice into keyed accessory wire that has power when key is turned on. You may need to use a test light to locate a suitable wire.
    CORDED REMOTE SWITCH INSTALLATION:
    NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

11. Install corded remote switch socket on vehicle dash. The recommended mounting location is inside the dash compartment located on right side of dash. The mounting hole locations have been marked as shown from the factory to aid in mounting.

12. Drill a 1” (25mm) diameter hole into the dash storage panel as shown, centered between dots embossed on dash. Drill two holes for screws with 5/32” (4.0mm) drill bit over embossed dots as shown in figures. (See illustrations 1-6 and 1-7).

13. Feed the corded remote harness thru the large hole and install the dash socket (item #24) using the supplied M5 flat washers and small screws into the dash as shown. (See illustrations 1-8 and 1-9). Note, the screws have thread-forming feature and will cut threads into plastic dash panel.

14. Torque screws to the specification listed, being careful not to overtighten.

15. Locate the area where the wire harness will pass thru the dash wall. Route the supplied remote vehicle harness (item #24) through the firewall towards front gearcase area. Use cable ties (item #10) to secure the harness. (See illustration 1 -18 and 1-20).

16. Attach the supplied red fused wire from harness kit (item #24) to the 12V accessory keyed power terminal post on the bus bar under the hood as shown. (See illustration 1-19).
    Note, the power accessory splitter harness (item #25) will be used to connect to the Dash Mount switch into the red fused wire section. Also, if connecting both corded remote and dash switch, the splitter harness will connect the two switches to accessory power.

17. Connect the white harness connector to the winch contactor connector as shown. Access is gained by reaching around the front bumper and thru the front gearcase access window to reach white contactor connector. (See illustration 1-20).

MOUNTING THE CONTACTOR/SOLENOID

• The contactor/solenoid is a primary safety feature in the winch system. It disconnects the winch from its power source when the vehicle is not in use. The contactor/solenoid must be correctly installed to work properly.
• Find a location for the contactor/solenoid. It is recommended that the contactor/solenoid be mounted close to the battery in a clean, dry location. The exact location of the contactor/solenoid will vary depending on the vehicle. Make sure the location chosen allows for sufficient clearance from all metal components such as frame tubes. DO NOT place tools or other items in a position that might come in contact with the contactor/solenoid posts.
• Some winch mounting brackets and/or vehicles could have an integrated contactor mounting location.
• Drill mounting holes if required. Secure the contactor/solenoid using the provided hardware.
• Some winch mounting brackets contain contactor mounting locations.
• Once a location is found for the contactor/solenoid, DO NOT install the unit until all wiring is completed (see wiring section). Pre-fit all wiring to confirm its long enough to reach the battery and the winch contact locations.

WARNING
NEVER short battery terminals with metal objects. Be aware terminals in contact with metal will cause a direct short, possibly causing contactor/ solenoid and/or battery damage.
WIRING THE WINCH

• Install the wiring using the diagram on the next page.
• Slip terminal boots on yellow and blue cable ends. Connect the yellow and blue cables to the color-matched motor terminals on the winch. Tighten the terminal nuts on the motor. DO NOT overtighten. Seat boots over terminal. Route the other ends to the contactor/solenoid location.
• Connect the yellow and blue cables to the contactor/solenoid (yellow to yellow and blue to blue). DO NOT tighten nuts or seat boots at this time.
• Slip terminal boots on the ring terminal ends of the black and red cables. Connect the black and red cables to the contactor/ solenoid (red to red and black to black). DO NOT tighten nuts or seat boots at this time. Route red and black cables to battery. DO NOT connect cables to battery at this time.
•  Mount the contactor to the location planned in the previous steps with provided hardware. Tighten the contactor/ solenoid mounting fasteners. DO NOT overtighten.
• Adjust cables to facilitate orderly and straight routing of the cables from the contactor/solenoid. Avoid kinks or sharp bends in the cables. Avoid crossing cables over each other for at least the first 6” of cable starting from the contactor/solenoid post. Tighten the contactor/solenoid terminal nuts. DO NOT over tighten. Seat terminal boots over ring terminals and posts.
• Connect the rocker switch to the contactor/solenoid using the provided plug. Splice the end of the red wire on the rocker switch, to a vehicle accessory circuit controlled by ignition controlled power source (keyed). The wire should only have power when the key is in the “ON” position.
• Carefully inspect battery and winch electrical cable routing to ensure it is neat and tidy. Secure electrical cables and wiring harnesses with provided cable ties. Cable ties should be snug, but not cutting into wire insulation. Use electrical tape, pieces of rubber hose or electrical conduit to protect electrical cables and wire harnesses where needed to avoid electrical cable insulation wear or abrasion.
• Reconnect the main vehicle power cables and the winch power red (positive) and black (negative) cables to battery terminals at this time using original hardware. Connect the red lead to the positive (+) terminal of the vehicle’s 12 volt battery first. Connect the black lead to the negative (-) terminal of the vehicle’s 12 volt battery second. Install protective boots as appropriate to protect connection. Tighten battery terminal fasteners as directed in the vehicle service manual to the proper torque specification.
• With vehicle key in the ON position, check winch for proper operation. Check for proper drum rotation. Pull and turn the clutch knob to the “free spool” position. Pull out some cable from the drum, and then turn the clutch knob to the “locked spool” position to engage the gears. Press the cable out button on the rocker switch. If the drum is turning and releasing more cable, your connections are accurate. If the drum is turning and collecting more cable, then reverse the leads on the motor. Repeat and check rotation.
•  With some applications, the motor terminal posts may need to be rotated to avoid interference with other components.

CAUTION
NEVER route electrical cables across any sharp edges, through and /or near moving parts, or near parts that may become hot.
CAUTION
ALWAYS leave some slack for electrical cable movement. Battery cables should NOT be drawn taut.
WINCH WIRING DIAGRAM
Electrical Connections Reference Guide

ATV/UTV WINCH USER GUIDE

Before you begin using your winch, read and understand the guide. Please retain this guide for future reference.
These safety warnings and instructions apply if you choose to add an accessory winch to your vehicle.
WARNING
ALWAYS follow all winch instructions and warnings in this manual. Improper winch use can result in
SEVERE INJURY or DEATH.
Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.
WINCH SAFETY PRECAUTIONS

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 17.

7. Always keep the area around the vehicle, winch, winch cable and load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s center line whenever possible.

12. If winching at an angle is unavoidable, follow these precautions:
    A. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
    B. If stacking occurs, stop winching. Follow step 15 on page 4 to feed and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch
    to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while winching a load.

17. Never let the winch cable run through your hands, even if wearing heavy gloves.

18. Never release the clutch on the winch when the winch cable is under load.

19.  Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs.

22. Always inspect your winch and winch cable before each use.

23.  Never winch the hook fully into the winch. This can cause damage to winch components.

24. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

WINCH OPERATION
Read the Winch Safety Precautions in the preceding pages before using your winch.
TIP: Consider practicing the operation and use or your winch before you actually need to use it in the field.
WARNING
ALWAYS follow all winch instructions and warnings in this manual. Improper winch use can result in
SEVERE INJURY or DEATH.
Each winching situation is unique:

• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.

1.  Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first three feet (one meter) of the winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s parking brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

4.  Always use the hook strap when handling the hook. WARNING
   NEVER put your fingers into the hook. This could lead to SEVERE INJURY.
   A. Attach the hook itself onto the load or use a tow strap or chain tosecure the load to the winch cable.
   TIP: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch.
   WARNING
   NEVER use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 17.
   B. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
   C. If possible, keep the winch cable aligned with the center line of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
   WARNING
   ALWAYS replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of a failure. For your safety, always replace
   KOLPIN winch parts (including the cable) with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website.
   D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to Tread Lightly® (treadlightly.org).
   E. Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when  the load is attached.
   F. Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

8. Read and adhere to the following information for winch damping to ensure safe winch use.
   A. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
   B. Lay the damper on top of the mid-point of the winch cable length that is spooled out.
   C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
   D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when the vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 17. For your safety, always follow these guidelines when winching a vehicle free:
    A. Release the winch clutch and spool out the necessary length of winch cable.
    B. Align the winch cable as close as possible to the winching vehicle’s center line.
    C. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following instructions in this manual.
    D. Re-engage the clutch on the winch.
    E. Slowly winch in the slack in the winch cable.
    F. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.
    G. Shift to the lowest gear available on the stuck vehicle.
    H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.
    I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch.
    J. Detach the winch cable hook.
    K. Rewind the winch cable evenly back onto the winch drum following the instructions in this manual.

12.  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.

13. 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.

14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

15. 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.
    A. Release the clutch on the winch.
    B. Feed out the winch cable that is unevenly bunched up in one area.
    C. Re-engage the winch clutch.
    D. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the hook strap.
    E. Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum.
    F. Doing this reduces the chances of the winch cable “wedging” itself between lower layers of winch cable.

WINCH CABLE CARE
For your safety, always replace KOLPIN winch parts (including the cable) with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website (Kolpin.com).
WARNING
NEVER use a worn or damaged cable. Use of a worn or damaged cable could lead to sudden failure and SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.
   B. A kinked winch cable made of wire rope that has been “straightened out” is shown at right. 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. Promptly discontinue use of a winch cable in this condition.
   C. A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.
   D. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

SHOCK LOADING
WARNING
NEVER shock load a winch cable. Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. 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.

1. 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
   NEVER use a broken winch cable. SEVERE INJURY or DEATH can result.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of 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.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

6. Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

WINCH MAINTENANCE AND SERVICE SAFETY

WARNING
ALWAYS follow all winch instructions and warnings in this manual. Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch
4. For your safety, always replace KOLPIN winch parts (including the cable) with KOLPIN replacement parts available at your authorized KOLPIN dealer or the KOLPIN website (Kolpin.com).
5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store.
   Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

WARNING
ALWAYS be aware that failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.
LUBRICATION
All moving parts within the electric winch have been lubricated using high temperature grease at the factory. No internal lubrication is required. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.
CABLE ASSEMBLY REPLACEMENT
It is recommended that only KOLPIN supplied parts be used.

1. Move the clutch to the “free-spool” position.
2. Extend cable assembly to its full length. Note how the existing cable is connected to the inside of the drum.
3. Remove old cable assembly and attach new one.
4. Retract cable assembly onto drum being careful not to allow kinking.

NOTE
For service or parts assistance, contact our help line at 1-877-956-5746.

PERFORMANCE SPECIFICATIONS

• Motor: 12V DC, permanent magnet type, heavy duty
• 1.0 HP ………………………………………..….……. 6000 lb. rated pull
• Motor duty cycle: Intermittent
• Gear reduction ratio ……………………………………….…… 200 : 1
• Brake: Mechanical
• Electric cable leads …………………………………….………. 6 gauge (6000 lb.)
• Winch cable size:
• 15.4m length x 6.6mm diameter wire rope ..………. 6000 lb. rated pull

25-9605 Kit Contents (6000 lb) and Replacement Part Numbers:

TROUBLESHOOTING

Motor does not turn| Switch assembly not connected properly| Insert switch assembly all the way into the connector.
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Loose battery cable connections| Tighten nuts on all cable connections.
Contactor malfunctioning| Tap contactor to loosen contacts. Apply 12 volts to coil terminals directly. A clicking indicates proper activation.
Defective switch assembly| Replace switch assembly.
Defective motor| Check for voltage at armature port with switch pressed. If voltage is present, replace winch assembly.
**** Nested and bounded cable within winch assembly| Move freespool knob to the “free spool” position. Manually pull cable out of winch

until end is met and then re-spool cable back into winch.

ater has entered motor| Allow to drain and dry. Run in short bursts without load until completely dry.
Motor runs but cable drum does not turn| Clutch (free-spool knob) not engaged| Move freespool knob to the “locked spool” position. If problem persists, a qualified technician needs to check and repair.
Motor runs slowly or without normal power| Insufficient current or voltage| The battery is weak, recharge. Run winch with vehicle motor running (battery should have a strong charge).
Loose or corroded battery cable connections| Clean, tighten, or replace.
Motor overheating| Winch running time too long| Allow winch to cool down periodically.
Motor runs in one direction only| Defective or stuck contactor| Tap contactor to loosen contacts.
Repair or replace contactor.
Defective switch assembly| Replace switch assembly.
Defective brake assembly| Replace winch assembly.

Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877-956-5746.
NOTE
For further technical support, contact our help line at 1-877-956-5746.
Five Year Mechanical Limited Warranty and Three Year Electrical Limited Warranty
For the period of five (5) years from the purchase date, Kolpin will replace for the original purchaser, free of charge, any mechanical part or mechanical parts found upon examination by Kolpin to be defective in material, workmanship, or both. For the period of three (3) years from the purchase date, Kolpin will replace for the original purchaser, free of charge, any electrical part or electrical parts found upon examination by Kolpin to be defective in material, workmanship, or both.
All transportation costs incurred submitting product to Kolpin for warranty consideration must be borne by the purchaser. If Kolpin determines that the product must be returned to the factory for credit, please call 1-877-956-5746 for a Return Merchandise Authorization (RMA) number and shipping instructions.
This warranty does not apply to parts that have been damaged by accident, alteration, abuse, improper maintenance, normal wear, or other causes beyond the manufacturer’s control. In order to protect you and your ATV, certain parts of the winch/plow system and/or hardware are designed to fail when the equipment is over-stressed. Parts that are lost due to loosening and improper maintenance are not covered under warranty. This warranty does not cover removal or reinstallation labor fees of the winch/plow system and related components.
Peripheral products such as engines, electric motors, and actuators may carry an original manufacturer’s warranty. Most hardware is general in nature and is easily obtained locally. Be sure to replace with minimum metric class 8.8 specification.

Kolpin Outdoors, Inc.
Telephone: (763)-478-5800
Toll Free: (877)-956-5746
Fax Number: (800)-245-7569
www.kolpin.com
Email:customerservice@kolpin.com
© 2022 Kolpin Outdoors Inc.
REV 00

Documents / Resources

| KOLPIN OUTDOORS 25-9605 Polaris Ranger 6000 lb Synthetic Rope Winch [pdf] Instruction Manual
25-9605, Polaris Ranger 6000 lb Synthetic Rope Winch, 6000 lb Synthetic Rope Winch, Polaris Ranger Rope Winch, Rope Winch, Winch
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References

• ATV & UTV Accessories - Protect & Transport Your Gear | Kolpin
• Home - Tread Lightly
• ATV & UTV Accessories - Protect & Transport Your Gear | Kolpin

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