WINCH 3500 AND 4500 KIT P/N 2879461; 2879462 Application RZR XP 1000 Before you begin, read these instructions twice and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information. 10 11 6 8 7 9 14 13 5 3 2 12 4 1 3500 Winch Kit Contents: Ref Qty Part Description Part Number 1 1 Winch-Polaris, 3.5 2204688 2 1 Hook-Latch, Winch 2411836 3 1 Roller-Fairlead, Winch 25/3500 2411848 4 1 Cable-Winch, Steel, 3/16 2878890 5 1 Contactor-Winch 4013465 6 1 Remote-Switch, Winch 4013466 7 1 Socket-Winch 4014228 8 1 Cable-Winch, Yellow 6 GA, 480mm 4013468-480 9 1 Cable-Winch, Blue 6 GA, 400mm 4013469-400 10 1 Power Cable, Winch, Black 6 GA, 375mm 4013470-375 11 1 Power Cable, Winch, Red 6 GA, 375mm 4013471-375 12 1 Power Bracket, Winch, Red RZN 5257962 13 1 Fairlead Bracket Mount, RZN 5257963 14 1 Cable-Assembly, Battery to Terminal Block 4014577 15* 2 -M5x0.8X208.8TXPH ZOD 7518980 16* 2 Nut-M5X0.8X8.8 HX/FL NYLOC 7547427 17* 4 -HXFL-M6X35 ZOD HILO 7519330 18* 6 Nut-M10X1.5 HFN NYLOC-ZOD 7547423 19* 4 Nut-M12X1.75, FLG, NYLOC-OLIVE D 7547441-1-
Ref Qty Part Description Part Number 20* 6 -RHCAR-MX10X1.5X25 8.8 ZOD 7519372 21* 4 -M12x1.75X25 8.8 HXFL ZOD 7519072 22* 4 -HXFL-M8X1.25X20 8.8 ZOD P3 7519133 23* 2 -SH-M10X1.5X25 8.8 ZPB D513 7517358 1 Instructions 9924528 1 Manual-Winch Guide 9923644 0 Service Kit Handle, HD Winch 2205265 Item marked (*) are included in Hardware Kit PN 2205119. 11 12 8 7 9 6 14 15 3 10 2 1 5 4 13 4500 Winch Kit Contents: Ref Qty Part Description Part Number 1 1 Winch-Polaris, 4.5, BTM SPL 2204855 2 1 Hook-Latch, Winch 2411836 3 1 Fairlead, HAWSE, MACH, WIDE 2879148 4 1 Stop-Magnet, Bumper, Rubber 5414619 5 1 Rope Kit, Winch, 45, UHMW 2879187 6 1 Contactor-Winch 4013465 7 1 Remote-Switch, Winch 4013466 8 1 Socket-Winch 4014228 9 1 Cable-Winch, Yellow 6 GA, 480mm 4013468-480 10 1 Cable-Winch, Blue 6 GA, 400mm 4013469-400 11 1 Power Cable, Winch, Winch, Black 6 GA, 375mm 4013470-375 12 1 Power Cable, Winch, Winch, Red 6 GA, 375mm 4013471-375 13 1 Power Bracket, Winch, Red RZN 5257962 14 1 Mount-Fairlead, 4.5, RZN 5258106 15 1 Cable-Assembly, Battery to Terminal Block 4014577 16* 2 -M5x0.8X208.8TXPH ZOD 7518980-2-
Ref Qty Part Description Part Number 17* 2 Nut-M5X0.8X8.8 HX/FL NYLOC 7547427 18* 4 -HXFL-M6X35 ZOD HILO 7519330 19* 6 Nut-M10X1.5 HFN NYLOC ZOD 7547423 20* 4 Nut-M12X1.75, FLG, NYLOC OLIVE D 7547441 21* 6 -RHCAR-MX10X1.5X25 8.8 ZOD 7519372 22* 4 -M12x1.75X25 8.8 HXFL ZOD 7519072 23* 4 -HXFL-M8X1.25X20 8.8 ZOD P3 7519133 24* 2 -SH-M10X1.5X25 8.8 ZPB D513 7517358 1 Instructions 9924528 1 Manual-Winch Guide 9923644 Internal Cam Service Kit (Includes internal cam 2205497 for freespool handle to connect winch to a replaceable handle, purchase handle separately) Service Handle (Includes freespool handle and screw) 2205265 Item marked (*) are included in Hardware Kit PN 2205119. Tools Required: Standard and Metric Socket Set Drill and Bit Set Philips driver APPROXIMATE ASSEMBLY TIME: 45 minutes Standard and Metric Wrench Set Torque Drivers 1 1/6 Hole Saw or Drill IMPORTANT: Your Polaris RZR XP 1000 WINCH 3500 and 4500 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. Before you begin, thoroughly review the instructions. Ensure you have all the required tools and the skills necessary to complete this installation. -3-
INSTALLATION INSTRUCTIONS 1. Place the vehicle in PARK and turn the key to OFF position. Remove the key from the vehicle. Remove the driver seat. Disconnect the black negative and the red positive battery cable from the battery. Figure 1. Battery Cables Under Seat Figure 1 2. Remove the hood from the vehicle by twisting the two knobs and pulling up. Figure 2. Knob Pull Figure 2 3. Remove the shift lever cap by using a flat screwdriver to remove the cap of the shift handle. Remove the handle screw with a T25 Torx bit retaining it for reuse and pull up to remove the handle from the shift lever weldment. Figure 3. Pull Cap Shift Housing Figure 3-4-
4. After removing shift lever cap and shift handle, take off the center console by removing the two screws (PN 7519650) and the four tuff lock rivets (PN 7661855). Figure 4. Lift Figure 4 5. Route the cable (PN 4014577) having red and black wires from bus bar to the battery. Clip the harness to specified locations.figure 5. NOTE: The red and black wires are supplied with the kit. Vehicle Front IMPORTANT: Do not connect the wire to the battery terminal at this step. Black Cable Red Cable Bus Bar Firewall Figure 5-5- Vehicle Front
6. Detach the plastic plate by removing two screws (PN 7518980). Figure 6. Figure 6 7. Take off the front fascia by removing six hexagonal screws (PN 7518529) and four screws (PN 7519650). Figure 7. Figure 7 Hexagonal 8. Mount the winch plate onto the vehicle with four screws (PN 7519372) and lock nuts (PN 7547423). Figure 8. Lock Nut Figure 8-6-
9. Connect the wires to the winch before installing it onto the vehicle. Figure 9. NOTE: Connect blue wire to the blue terminal and yellow wire to the yellow terminal (color coding is already provided on winch). Figure 9. Yellow Wire Blue Wire Figure 9 10. Slide winch (PN 2204688 and PN 2204855) from left to right direction on the plate. Figure 10. Slide Figure 10 11. Mount and fix the winch (PN 2204688 and PN 2204855) onto the plate with four screws (PN 7519133). Figure 11. Figure 11-7-
12. Lead mounting: a) For 3500 Winch: Mount the roller fair lead (PN 2411848) onto the front plate bracket (PN 5257963) with two screws (PN 7519372) and nuts (PN 7547423). Figure 12. b) For 4500 Winch: Mount the fair lead (PN 2879148) onto the front plate bracket (PN 5258106) with the two screws (PN 7517358) and nuts (PN 7547423). Figure 13. Front Plate Bracket Roller Fair Lead Figure 12 Front Plate Bracket Fair Lead 13. Front Plate Bracket installation: a) For 3500 Winch: Install the front plate bracket (PN 5257963) with roller fair lead (PN 2411848) as subassembly on the vehicle with the four bolts (PN 7519072) and nuts (PN 7547441). Figure 14. Figure 13 b) For 4500 Winch: Install the front plate bracket (PN 5258106) with fair lead (PN 2879148) as subassembly on the vehicle with the four bolts (PN 7519072) and nuts (PN 7547441). Figure 15. Figure 14 Bolt Bolt Figure 15-8-
14. Cable installation: a) For 3500 Winch: Twist the knob on the winch (PN 2204688) and insert the cable through front plate bracket (PN 5257963) and roller fair lead (PN 2411848) to move the cable freely. Figure 16. b) For 4500 Winch: Twist the knob on the winch (PN 2204855) and insert the cable through front plate bracket (PN 5258106), fair lead (PN 2879148) and rubber stop (PN 5414619) to move the cable freely. Figure 17. Knob Figure 16 Pull Knob Stop Rubber Figure 17 Pull -9-
15. Hook attachment: a) For 3500 and 4500 Winch: Attach the hook (PN 2411836) with the cable by inserting the clip through it. Figure 18 and Figure 19. Attachment Point to Vehicle Hook Figure 18 Attachment Point to Vehicle Hook Figure 19-10-
16. Mount the winch contactor (PN 4013465) on the firewall with the four bolts (PN 7519330) at the specified drilled holes. Figure 20. NOTE: Ensure that the yellow color code on the contactor is on top. Bolt Figure 20 17. Connect the blue (PN 4013469), yellow (PN 4013468), red (PN 4013471) and black wires (PN 4013470) to the contactor terminals and put the caps. Figure 21. NOTE: Color coding for terminals will be on contactor (PN 4013465). Yellow Wire Red Wire Black Wire Figure 21 Blue Wire 18. Hook up the negative (black) (PN 4013470) and positive (red) (PN 4013471) terminals to the bus bar. Figure 22. Negative Black Positive Red Figure 22-11-
19. Feed the socket wires from inside of cab through the grommet in the firewall. Figure 23. NOTE: Socket position may change as per requirement. Socket Wire Figure 23 For 3500 Winch 20. Plug in the socket wire connector to the contactor connector (PN 4013465). Figure 24. Cabin Firewall Grommet Figure 24 Contactor 21. Connect the red socket wire to the accessory bus bar. Figure 25. Red Wire Bus Bar GND ACC BAT Figure 25-12-
For 4500 Winch 22. Connect the connector from fairlead to auto stop control unit connector. Figure 26. Fairlead Connector Control Unit Connector Figure 26 23. Route the wire from fairlead to the auto-stop control unit. Figure 27. NOTE: Use panduit straps to secure the cable from hot or moving parts. Auto-stop Control Unit Cable Figure 27 Fairlead 24. Route the cable (highlighted) from auto-stop control unit to the bus bar. Figure 28. NOTE: Use red ring terminal adapter in part number 2879148 and connect it to terminal to acc location on bus bar. Install the black ring terminal to the negative location on the buss bar. Cable Figure 28-13-
25. Route the cable from auto-stop control unit to the socket wire connector (PN 4014228). Figure 29. Bus Bar Firewall Socket Winch Cable Figure 29 Auto-stop Control Unit Socket Wire Connector 26. Route the cable (highlighted) from auto-stop control unit to the contactor. Figure 30. Firewall Bus Bar Socket Winch Cable Figure 30 Contactor Connector Auto-stop Control Unit For 3500 and 4500 Winch Kits: 27. Cut out a hole in the din box for mounting the socket (PN 4014228). Figure 31. Hole NOTE: Follow the instruction on the back of the din for the cutout. NOTE: Position may change as per requirement. Figure 31-14-
28. Drill the mounting holes to the specified location around the cut out of the socket on the back of din box. Figure 32. NOTE: Use 1/4 drill bit. Figure 32 Hole in din box Mounting hole in socket 29. Attach socket (PN 4014228) onto the din box with two bolts (PN 7518980) and two nuts (PN 7547427), at specified position. 30. Install the remote with the socket which is attached to the din box. Figure 33. 31. Connect the negative and positive cable to the battery which was disconnected in Step 1. 32. Attach the front fascia, center hood, center console, shift lever housing with cap and finally install the seat to its position which were disconnected in Steps 7, 2, 4, 3 and 1 respectively. Bolt Figure 33 P/N 9924528 Rev 03 01/14-15-