To Next PageTo Next PageWhy is my Polaris PRO HD 4500 WINCH KIT operating so slowly?
If your Polaris Winch is operating too slowly, ensure the gear knob is set to the correct gear. Also, the winch's speed can be affected by the load on the rope or if the rope is tangled within the spool. Check that the winch is unobstructed, the rope isn't bound, and there's no load on the rope.
Why my Polaris PRO HD 4500 WINCH KIT winch will not operate?
If your Polaris Winches winch will not operate, first ensure the vehicle key is turned on. Then, check that the wireless remote is powered on. Verify the connections between all components are correctly aligned. A direct connection of the wired handlebar switch from the vehicle's main wire harness to the contactor can help determine if the winch will operate directly. Also, check the fusebox for the 10A accessory circuit and voltage in the orange wires near the steering post.
What to do if my Polaris PRO HD 4500 WINCH KIT makes noise but the rope does not move?
If your Polaris Winches winch makes noise but the rope doesn't move, the contactor might be powered while the winch isn't. Check the connections between the winch and the contactor. Also, verify that the winch is properly engaged in gear. If it's in gear and still not moving, a dealer inspection is recommended.
What to do if my Polaris Winches operates in one direction only?
If your Polaris Winches winch operates only in one direction, check the connections of the Autostop fairlead. If the winch only operates outward, make sure the black rubber puck isn't touching the aluminum fairlead. If it operates inward even when the puck is touching, check the Autostop control box connections. If it operates inward but not outward when the puck is touching the fairlead, check that the wire colors at the connectors match on both sides.
Why Polaris PRO HD 4500 WINCH KIT Winches winch will not change gears?
If your Polaris Winches winch won't change gears, it's likely because the rope is under load. Ensure there's no tension on the rope and that it's not bunched up inside the spool area. Operate the winch briefly, then try shifting again.
Read instructions and check parts/tools before installation. Retain for future reference.
Shift vehicle to PARK, turn key OFF, remove seat, remove hood, and remove shift knob.
Route red and black power cables from battery to bus bar, but do not connect them yet.
Align and install winch mounting bracket, connect cables, and install autostop fairlead.
Mount contactor on firewall using screws and connect cables to terminals.
Position control box behind radiator and connect electrical connectors.
Mount receiver on chassis, connect power wires to bus bar and ground.
Install wireless remote holder in desired location using supplied screws.
Reinstall front fascia, headlights, console, shift knob, hood, battery cables, and seat.
This document describes the installation and operation of the Polaris PRO HD 4500 Winch Kit, designed exclusively for Polaris vehicles. The kit includes the winch assembly, various cables (yellow, blue, black, red), a latch hook, a control box, rope, a wireless remote kit, a contactor, an autostop fairlead, winch and fairlead mount brackets, a rubber stop magnet, and various screws and nuts for installation. A separate power cable kit is required for most models, with the exception of the MY17 RZR Turbo, which comes pre-wired for winch installation.
The Polaris PRO HD 4500 Winch Kit provides a powerful winching solution for Polaris vehicles, enabling users to pull loads and recover their vehicle or other objects. Key components work together to ensure safe and efficient operation. The winch assembly, powered by the vehicle's electrical system, spools and unspools the rope. The contactor acts as a relay, controlling the flow of power to the winch. The control box manages the winch's functions, while the wireless remote allows for remote operation, enhancing safety by enabling the user to stand clear of the vehicle during winching. The autostop fairlead and rubber stop magnet are integral to the Autostop system, which prevents over-tightening of the rope and potential damage to the winch.
Installation: The installation process involves several preparatory steps, including shifting the vehicle into "PARK," turning off the ignition, removing the driver's seat, disconnecting the battery (negative cable first), removing the hood, shift lever cap, center console, plastic winch cover, front fascia, and headlight connectors. Once the vehicle is prepared, the power cable kit (if required) is routed from the battery to the bus bar terminals, ensuring not to connect them at this stage.
The winch mounting bracket is then installed onto the chassis and front suspension brackets using screws and nuts, torqued to specification. The winch assembly is slid onto the mounting bracket and secured with screws, also torqued to specification. The blue and yellow winch cables are connected to their corresponding color terminals on the winch assembly. The autostop fairlead is installed onto the fairlead mounting bracket.
The winch rope is fed through the fairlead mounting bracket, autostop fairlead, and rubber stop, with the winch hook installed onto the rope. A helpful hint suggests attaching a plastic cable tie to the end of the rope to feed it through the rubber stop, using a mild lubricant if needed.
The contactor is installed onto the firewall using screws, tightened until snug but not overtightened. The blue, yellow, red, and black cables are connected to the contactor terminals and torqued to specification. Power wires from the control box are routed to the bus bar, connecting the red positive wire to the orange, keyed power terminal and the black negative wire to the black (ground) terminal. All remaining wires are secured with cable ties.
The wireless remote receiver is mounted onto the chassis, and its electrical connectors are connected. Its power wires are routed to the bus bar, connecting the red positive wire to the keyed power terminal and the black negative cable to the ground terminal. All remaining power wires are secured.
Wireless Remote Operation: The wireless remote holder can be installed in a desired location on the vehicle. To use the remote, hold the "On/Off" button for three seconds until the LED light turns on. The remote will operate the winch if the vehicle is on and the winch is receiving power. The remote automatically turns off after 30 seconds of inactivity and needs to be turned back on for subsequent use. To manually turn off the remote, hold the "On/Off" button for three seconds until the LED light turns off.
Autostop Operation: The Autostop system is designed to prevent damage from over-tightening the rope. It functions when the black rubber puck nears the aluminum fairlead, triggering sensors that prevent the winch from pulling in the rope further. It is important to note that this system is a secondary preventive measure, and the operator is always responsible for proper winch usage.
Gear Selection: The winch features three gear settings: High, Neutral, and Low.
Important Safety Note for Gear Shifting: Attempting to shift the winch while the rope is under tension is dangerous and can result in injuries or death. Always ensure the winch rope is not under tension before shifting between gears.
Troubleshooting: The manual provides a comprehensive troubleshooting guide for common issues:
Final Inspection: After installation, confirm all wiring is correct, ensure no exposed wires or terminals, and secure all loose wires away from moving parts and heat sources. Verify that the Autostop is functioning properly.
Reinstallation: The final steps involve reinstalling the front fascia, headlight connectors, center console, shift knob and lever cap, hood, main vehicle battery cables, power cable kit cables, and finally, the seat.
General| Gear Ratio | 166:1 |
|---|---|
| Line Type | Steel Cable |
| Rope Length | 50 ft |
| Pulling Capacity | 4500 lbs |
| Rated Line Pull | 4500 lbs |
| Voltage | 12V |
| Fairlead | Roller |
