BAD DAWG BD124030 Electric UTV Kit Instructions
- June 5, 2024
- BAD DAWG
Table of Contents
BAD DAWG BD124030 Electric UTV Kit
Assembly Components
Ensure that you have all of these components before beginning the installation.
What’s in the box
- 1 x Winch
- 1 x Nylon Rope
- 1 x Winch Hook
- 1 x Fairlead
- 1 x Electronic Control Module
- 1 x Winch Control Switch
- 4 x Electric Connector Cables
- 1 x Circuit Breaker Box
- 1 x Switch Harness
- 1 x External Control Assembly
- 1 x Circuit Breaker Cable
- 1 x Hardware kit
- 1 x Instructions Packet (includes circuit breaker)
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- 1 x Battery Assembly
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- 1 x Electric UTV Harness
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- Only included with the kit specific to electric UTVs
There are several electronic components necessary for proper installation that are not included in the winch kit but may be found at any hardware store. They include:
- 3 x Female Spade Connectors
- 2 x Self-tapping 1” Screws
- 1 x Piggy-back Wire Connector
- Additional Zip Ties as Necessary
Safety
Ensure that the UTV is safely parked on level ground with the ignition off Wear all appropriate PPE for the following procedures.
Note
- Leave all hardware loose until the entire assembly is in its final position.
- Included in these instructions are steps that only apply to electric UTVs. Those steps are indicated by an (E) at the beginning of the step description.
Instructions Steps
Attach the yellow and blue cables to the winch at the color-matched connection points. Be sure that the eyelets of the cables are firmly sandwiched between the copper washers
Place the winch onto the machine’s winch mounting plate with the yellow end cap on the driver’s side and the cables on the passenger side.
- Secure the winch to the mounting plate utilizing the hardware from the hardware kit.
- Place a lock-washer onto each bolt, followed by a flat washer before threading it through the bottom of the winch plate and into the base of the winch.
Locate the auxiliary battery mounting location on the UTV and mount the battery kit with the included carriage bolts and nuts
Mount the winch control box to a section of the UTV frame with the electronic contacts easily accessible
- Connect the yellow and blue cables from the winch to the corresponding contacts on the controller. For cleaner installation
- pre-measure and cut the wires before installing new eyelet connectors. Or, simply loop the cables and secure them with a zip tie away from moving parts
Assemble the circuit breaker kit with the positively indicated terminal connected to the short red cable. Enclose the circuit breaker inside of the black box labeled “circuit breaker”
- Connect the newly assembled red circuit breaker cable and the included black cable to the battery with their corresponding colors.
- Then attach the other ends of the cables to the corresponding locations on the winch controller module
The UTV is equipped with a DC/DC converter. To install the winch wiring harness, several wires must be accessible which will include the removal of the glove box compartment
Remove the glove box compartment or other structures to gain access to the DC/DC converter wire Deutsch connectors
- Unplug the Deutsch connections on the converter from the UTV harness. Keep all connectors within reach.
- The winch wiring harness is equipped with Deutsch connectors that correspond with the connectors on the 60 AMP (largest) converter.
- Connect each connector with its corresponding plug. Triangle to triangle, square to square, male to female.
- *Note: Check winch wiring harness for correct pin locations. Relocate pins if necessary.
- Route the red and black wires of the harness to the corresponding terminals on the battery
Locate the winch control switch harness and the included dash switch. Replacing the switch is optional, but will allow the switch to be installed directly into the dash of the UTV
Cut off the factory switch and strip the cable and wires in order to add female spade connectors
Add a piggy-back connector to the lone red twire
Route wires with the spade connectors through an open spot in the dash and attach to the new switch at the correct terminals before pressing the switch into the dash
- Connect the green and black connectors at the opposite end of the switch cable to the top of the winch controller
- Figure 6 of the winch installation manual details the wiring in a schematic for reference.
Connect the red wire to the open connector on the winch wiring harness. No connector is needed
- Connect the red wire with the piggy-back connector to the 12V accessory port.
- Install the fair lead on the front of the UTV. Any sharp edges that extend inside of the fairlead must be removed before the rope is installed
Install the synthetic rope by first inserting the taped end into the receiving hole in the spool and tightening the Allen screw to secure the rope inside of the spool
Have another person slowly wind the spool with the control switch while you guide the rope onto the spool evenly and without any twists in the rope
Once the rope is fully retracted, install the hook and pull strap
Make sure to secure all wires away from moving parts and to replace any panels, glove box compartments, etc. before operating the winch or the UTV.
EXTERIOR CONTROL SWITCH – OPTIONAL
Locate the exterior control switch and the jack plug harness included with the kit
Install the jack plug at the desired location on the UTV. Mounting holes may need to be cut/drilled in order to fasten the jack to plastic body parts
Route the jack harness to the winch control module and connect the black and green wires to their corresponding locations, as shown in Figure 24: Switch to Controller Wiring. Connect the red wire to the 12V accessory charger in the dash. (E) Connect the red wire to the open connector on the winch wiring harness.