KOLPIN Honda Talon 1000 Quick-Mount 4500lb Winch Kit Instructions

Honda Talon 1000 Quick-Mount 4500lb Winch Kit
Instructions

Honda Talon 1000 Quick-Mount 4500lb Winch Kit

Honda Talon 1000 Quick-Mount
4500lb. Winch Kit
Product Instructions
Part No : 26-1050
Application: Honda Talon 1000, verify accessory fitment at Kolpin.com.
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 information.
Note: If any hardware is missing, do not return to the store. Call us to help, Toll-Free 1-877-956-5746.

This Kit includes:

Tools Required:

• Safety Glasses
• Socket Set, Metric
• Drill or cutting tools for plastic
• Hex Key Set, Metric
• Wrench Set, Metric| • Socket Set, Torx Bit
• 1” Hole Saw or Drill Bit
• Electric Drill or Dremel tool
• Pliers
• Torque Wrench
• 9/64” Drill Bit
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Assembly Time: Approximately 30 minutes
Note: The 26-1050 kit comes mostly assembled from the factory. Some assembly is required.
Important: Your Kolpin Talon 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, perform all installation steps correctly in the sequence shown. Additional time may be required to accommodate other installed accessories.

TALON 1000 PREPARATION:

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

2. To gain access to electrical connections, turn the hood knobs, pull upwards to release tabbed grommet holds and remove the hood as shown. (See illustrations 1-1).

3. Locate the battery box, release clips and remove the cover. Disconnect black (negative) and red (positive) cables from the battery.(See illustrations 1-2).
   WARNING
   ALWAYS disconnect the black negative (-) cable from the battery FIRST. Failure to do so will result in a high current electrical arc, and may result in battery explosion if tool touches the grounded to frame. Death or serious injury may occur.

4. Remove the bumper screws from each side and front bumper as shown. Save all for re-install later. (See illustrations 1-3 and 1-4).
   Note, the 5mm, 6mm and 10mm bolts will be re-used for bumper installation later. This winch can be used with the stock bumper and Honda Signature Accessory Front Bumper (see illustrations 1-12).
   

5. Remove the Talon winch assembly from the packaging.
   NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

6. Position the winch sub-assembly into the front bumper as shown. (See illustrations 1-5).

7. Assemble the mounting bracket to the front bumper using the U – Bracket Clamps (item #15) and two M10 long bolts (item #26). Place the U-Bracket over the bumper frame tube as shown. Insert the bolts thru the winch bracket and U – Bracket and then fasten from the bottom using two M10 locknuts (item #18). (See illustrations 1-6, 1-7, and 1-8). Note, do not tighten the hardware at this time.
   

8. Locate the yellow and blue wires on the winch assembly. If they are secured together as a bundle with a plastic tie, cut the tie to allow the wires to be routed properly. Then
   locate the black cable tie (item #28) and close around the blue and yellow cables, securing them to the winch mount (item #4). (See illustrations 1-6 and 1-7).

9. Install winch-bumper assembly onto the frame re-using the OEM hardware removed in step 4 as shown. Check that all wires are free to move and not pinched between the vehicle chassis and the winch-bumper assembly. Route the blue and yellow power cables first into the window above the front gearcase, up behind the radiator. (See illustrations 1-8, 1-9, and 1-11). Note, do not tighten the hardware at this time.

10. Install the Frame Clamps (item #11) onto the back side of the vertical frame tubes, lining up with the winch mount plate(item #4) as shown. Fasten the clamps by inserting M8 screws (item #32), M8lock washers (item #31), and M8 flat washers (item #19) through the winch mount plate holes. (See illustrations 1-9, 1-10, and 1-11).
    

11. Tighten the OEM bumper hardware to the specifications listed below: four M8 upper bumper screws, two M8 lower bumper screws, two M6 upper plastic grille screws, and two M5 lower plastic grille screws.

12. Tighten the Winch Mount M10 and M8 hardware as specified below. (See illustrations 1-13).

13. To gain access to install Contactor (item #12), remove the rear hood by removing hex socket screws, flange screws, and plastic trim clips. The blue and yellow power cables can be pulled up behind the radiator. (See illustrations 1-14). Note, the rubber splash shield can remain in place, but can be folded down for cable routing access.
    

14. Locate the black and red power cables secured to the instrument panel at the location shown. Remove the blue protective tape from the terminals. (See illustrations 1-15).

15. Install a black rubber insulated terminal boot over the end of the black and red power cables as shown. Install the M6 screw (item #16) onto the contactor mount tab and fasten from the backside using the M6 locknut(item #27). (See illustrations 1-16). Note, do not tighten the hardware at this time.
    

16. Install the contactor (item #12) to the frame tab as shown using two M6 screws (item #16) and fasten using an M6 locknut (item #27) from underneath. (See illustrations 1-17  and 1-18). Note, do not connect the winch cables to the battery at this time.

17. Install the black and red power cables to the corresponding colored contactor terminals with the provided M6 nut as shown. (See illustrations 1-17 and 1-18). Note, the insulated black rubber boot terminals are not shown for clarity. Make sure to install the rubber boots onto the cable terminals for contactor stud terminals. Do not tighten M6 contactor nuts at this time.
    

18. Route the blue (item #9) and yellow (item #8) power cables along frame tubes, behind the radiator, over the front left shock, as shown to the contactor location. Secure the wires using plastic cable ties (item #2) to the frame tubes at the four locations shown. (See illustrations 1-19, 1-20, 1-21 and 1-22).

19. Install the blue and yellow power cables to the corresponding colored contactor terminals with the provided M6 nut as shown. (See illustrations 1-17 and 1-18).
    

20. Tighten the M6 Contactor nuts to the below specifications.
    

21. Slide the insulated rubber terminal boots over the four contactor stud terminals. (See illustrations 1-17).

22. The front bumper and winch installation steps are complete as shown and the following steps are for the control switch installations. TALON 1000 CORDED REMOTE SWITCH INSTALLATION:
    NOTE: See the Electrical Connections
    The reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

23. Remove the glovebox from the vehicle dash panel by removing the screws and plastic trim clips as shown. Save for reinstall later. (See illustrations 1-24). Note, there is a plastic trim clip deep inside the bottom of the glovebox that will need to be removed.
    

24. Remove the glovebox door by gently flexing the plastic at the hinge to free the hinge pin, then pull outwards to release.

25. The interior top surface of the glovebox is marked with three index locations as shown. Drill thru the plastic wall at the outer two holes using a 9/64” (3.5mm) diameter bit. Drill the center hole using 1” (25mm) diameter bit. (See illustrations 1-25).

26. From inside the glovebox, feed the corded remote harness thru the large hole and install the dash socket flange connector (item #22) using the supplied M5 flat washers (item #25) and small screws (item #24) into the glovebox panel as shown. (See illustrations 1-26 and 1-27).

27. Torque screws to the specification listed, being careful not to overtighten. NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

28. From behind the dash, locate the accessory socket and disconnect the vehicle’s main harness connector as shown. (See illustrations 1-28 and 1-29).
    

29. Install and connect the Talon Accessory Power Harness (item #20) to the accessory socket and to the main vehicle harness as shown. (See illustrations 1-30 and 1-31).

30. Reinstall the glovebox using the OEM fasteners.
    
    NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

31. Now connect the Accessory Power Splitter Harness (item #23) into the Corded Remote harness red lead (item #22) and Accessory Power Harness red receptacle connector (item #20). Secure and bundle the winch harnesses using a plastic tie (item #2) as shown. (See illustrations 1-31 and 1-32).
    Note, the power accessory splitter harness will also be used to connect to the Dash Mount switch.

32. Route and connect the white harness connector from the Corded Remote harness (item #22) to the winch contactor connector as shown. (See illustrations 1-33). NOTE: See the Electrical Connections Reference Guide section of the instruction manual for detailed photos of each part and their respective connections.

33. Install the dash mount switch (item #1) to the 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 1-34, 1-37, and 1-38). Note, the pattern shown in 1-38 may not be printed to scale.

34. Connect the dash mount switch (item #1) to the Talon Vehicle Dash Switch Harness (item #21). Connect green wire to the “Out” pin, red wire to the middle pin, and black wire to the “In” pin as shown. (See illustrations 1-35 and 1-36).
    

35. Insert the dash switch harness and switch assembly thru the panel hole as shown. The switch will clip into the dash panel. (See illustrations 1-36).

36. From under the hood area, on the firewall, connect the red lead wire from the dash switch harness into the Accessory Power Splitter Harness (item #23) red wire receptacle, as mentioned in previous step 31. (See illustrations 1-32).

37. Route the remaining length of the dash switch harness (item #21) along the Corded Remote Switch harness (item #22), previously installed in step 32, to the contactor location. Connect the dash switch white connector into the pigtail corded remote harness white connector as shown. Secure wire bundle using plastic cable tie (item #2). (See illustrations 1-33).

38. From the battery box location, find the Red Power Wire with the angled battery terminal. The red wire is behind the gray relays. Remove the blue protective tape from red
    wire terminal. (See illustrations 1-39 and 1-40). Note, the starter relay can be removed by sliding the rubber strap off the battery box plastic standoff tab.
    

39. Remove the left starter relay terminal boot and connect the red wire to the starter terminal as shown. (See illustrations 1-41).

40. Reinstall terminal boot and return rubber relay strap to the battery box plastic standoff tabs.
    TALON 1000 FINAL INSPECTION:

41. Confirm that all wiring is correct.

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

43. All loose wires need to be wrapped tight and secured away from moving parts and heat sources.
    TALON 1000 REINSTALLATION:

44. Reconnect the main vehicle power cables and the winch power red (positive) and black (negative) cables to battery terminals at this time using the original hardware.

45. Reinstall the rear hood, front hood, and battery box cover.

46. Connect the corded winch remote switch (item #22). (See illustrations 1-26).

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

CONTROL SWITCH OPERATION:
When properly installed, the control switch(es) allows you to operate the winch while seated in the vehicle using the dash switch or remotely using the corded switch. Proper switch operation is shown. (See illustrations 1-42).
For additional assistance, please contact Kolpin’s customer service department at 877-956-5746 or 763-478-5800 or email [email protected]
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 by submitting a 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.

TROUBLESHOOTING

If your winch is not functioning properly, below is a short guide that can help you diagnose and correct the problem.

Winch will not
operate| Contactor not receiving power| Turn the vehicle key on.
Connections between components not in proper order| Check connections. Connect the wired handlebar switch connection from the vehicle main wire harness directly to the contactor to make sure a direct connection will operate the winch. If connections are not in the order shown in the pictures on the last page, the whole system may not function or only certain parts of it will function.
Loose battery cable connections| Tighten nuts on all cable connections.
Keyed power circuit (orange wires) not properly powered| Check fusebox for 10A accessory circuit. Check the voltage in certain places, especially the orange wires coming out of the main harness by the steering post.
Contactor malfunctioning| Tap the 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 the winch assembly.
Nested and bounded cable within winch assembly| Move the free spool knob to the “free spool” position. Manually pull the cable out of the winch until the end is met and then re-spool the cable back into the winch.
Water has entered the motor| Allow draining and dry. Run in short bursts without load until completely dry.
Winch makes
noise but rope
does not move| Contactor powered, but not winch| If you can hear a clicking sound when you press the winch control but the winch does not make any sounds, check the connections between the winch and the contactor.
Winch not in proper gear| Move the free spool knob to the “locked spoor position, then recheck. If the problem persists, a qualified technician needs to check and repair it.
Winch operates too
slowly| Winch improperly loaded| Check that the winch is clear and the rope is not bound up and that there is no load pulling on the rope.
Insufficient current or voltage| The battery is weak, recharge. Run winch with vehicle motor running (the battery should have a strong charge).
Loose or corroded battery cable
connections| Clean, tighten, or replace.
Winch overheating| Winch running time too long| Allow the winch to cool down periodically.
Winch operates in
one direction only| Defective or stuck contactor| Tap the contactor to loosen contacts.
Repair or replace the 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 helpline at 1-877-956-5746.
ELECTRICAL CONNECTION REFERENCE GUIDE:
Talon 1000:
Winch with Roller Fairlead, Dash Switch, and Corded Remote Switch

Talon 1000:
Winch with Roller Fairlead and Dash Switch Talon 1000:
Winch with Roller Fairlead and Corded Remote Switch

References

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

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