The document is an Installation and Operations Manual for the VIPER ATV/UTV Winch Series, covering the VIPER Classic, VIPER Max, and VIPER Elite models. It provides detailed information on the winches' features, replacement parts, safety precautions, installation instructions, operation, troubleshooting, and warranty.
Function Description
The VIPER ATV/UTV Winch Series is designed for pulling loads in off-road and utility vehicle applications. These winches are electrical devices equipped with a permanent magnet motor, designed for intermittent duty winching. They are primarily used for self-recovery and moving loads, not for hoisting overhead or lifting people. The winches are built to withstand extreme conditions, provided they are regularly cleaned, inspected, and serviced.
Important Technical Specifications
The manual outlines replacement parts for several models, including EX3000/EX3500/EX4000/EX4500/EX5000/SE4000/SE4500/SE5000, MX3500/MX4000/MX4500/MX5000, and MX2000/MX2500/MX3000/VX2000/VX2500/VX3000/VX3500/VX4000.
Key components and their part numbers include:
- Drum Support, Motor: EX201 (EX series), MX113 (MX series)
- Drum Bushing: EX202 (EX series), MX114 (MX series)
- X-Ring, Seal: EX203, EX207, EX229 (EX series), MX116 (MX series)
- Drive Shaft Coupler: EX204 (EX series), MX131 (MX series)
- Drum Assembly: EX206 (EX series), MX115 (MX series), MX008 (MX/VX series)
- Motor Assembly: EX219 (EX series), MX124 (MX series), MX023 (MX/VX series)
- Contactor: MX129 (MX series), MX027 (MX/VX series)
- Freespool Knob: EX235 (EX series), MX110 (MX series), MX020 (MX/VX series)
- Freespool Dial Retention Ring: EX236 (EX series), MX109 (MX series), MX019 (MX/VX series)
- Brake Disc: EX227 (EX series), MX123 (MX series)
- Carrier Assembly Stages: EX213, EX214, EX216 (EX series), MX103, MX104, MX105 (MX series), MX003, MX013, MX014 (MX/VX series)
- Wiring Assembly: MX128 (MX series), MX026 (MX/VX series)
Winch Series Comparison:
| Feature |
Classic Series |
Max Series |
Elite Series |
| Winch Warranty |
6 months |
1 year |
2 years |
| Electrical Components Warranty |
6 months |
1 year |
1 year |
| Waterproof |
Fully Sealed |
Fully Sealed |
Fully Sealed |
| Mini Rocker Switch |
Included |
Included |
Included |
| Cabled Remote Switch |
Extra Charge |
Included |
Extra Charge |
| Wireless Remote Switch |
Extra Charge |
Extra Charge |
Included |
| Dashboard Mounted Switch |
Extra Charge |
Extra Charge |
Extra Charge |
| 50' Steel Cable |
Included |
Included |
N/A |
| Amsteel Blue Synthetic Cable* |
Extra Charge |
Extra Charge |
Included |
| 4T Snatch Block |
Extra Charge |
Included |
Included |
| Winch Cover |
Extra Charge |
Included |
Included |
| Rubber Line Stopper |
Extra Charge |
Included |
Included |
| Upgraded Contactor |
Extra Charge |
Included |
Included |
| Rubber Terminal Boots |
Extra Charge |
Included |
Included |
| Elite Greasing System |
N/A |
N/A |
Included |
*Max & Classic winches can be upgraded to either 3/16" or 1/4" diameter synthetic cable.
**Dashboard mounted switches are included with UTV style winches (wide spool).
Steel cable is not included on winches with synthetic cable.
The Elite winches come standard with 1½" diameter cable.
Load Capacities:
- Maximum working load capacity is on the first layer closest to the drum.
- For loads over 1,000lbs, the use of a snatch block is recommended to double line the cable, reducing the load by approximately 50%.
Usage Features
Installation:
- Mounting: Recommended to use an ATV/UTV-specific mounting kit. Winches can be mounted with the cable coming from under or over the spool, depending on the vehicle.
- Electrical: Disconnect battery connections before working with the winch. Attach wires to motor or contactor terminals by holding the inner nut with a wrench while tightening the outer nut.
- Contactor Location: Mount close to the battery in a clean, dry location, ensuring sufficient clearance from metal components.
- Switch Mounting: Typically mounted on the left handlebar. Route wiring harness back to the contactor, connecting the red wire to a key-controlled electrical wire.
- Battery Connection: Route wires near the battery, switch, mounting point, and winch, ensuring they do not interfere with hot or moving engine, suspension, steering, braking, or exhaust parts.
Operation:
- Freewheel/Freespool: Move the freewheel clutch knob to disengage. Do not force the knob if there is load on the drum; release tension with "power out" function. Pull out the desired length of cable, ensuring at least five turns remain on the drum. Re-engage the drum before winching. Never attempt to free or engage the knob while the drum is turning.
- Cable Guidance: Cable must be guided when spooling onto the winch to prevent damage. Stop and re-align if the cable is not winding evenly.
- Safety: Stand clear of the wire rope during winching. Never put fingers through the hook. Ensure the rope is taut when moving a load.
- Amsteel-Blue Synthetic Cable: Use a sliding 5' abrasion guard at points of tension (e.g., around trees, over sharp objects). Use a hawse fairlead; gently sand smooth any dings.
Troubleshooting:
- Motor not operating/runs one direction: Check switch, wiring, connections, or motor.
- Motor runs hot: Allow to cool or replace/repair motor.
- Insufficient power/line speed: Check battery, charging system, wire length, battery terminals, ground, or motor.
- Motor runs but drum doesn't turn: Engage clutch.
- Winch runs backwards: Recheck motor/switch wiring.
- Winch will not hold load: Reduce load or double line.
- Contactor runs one way/hums: Tap with hammer to break apart connections.
Maintenance Features
General Maintenance:
- Cleaning: Winch should be cleaned, inspected, and serviced regularly, especially after use in mud, sand, silt, or water, as these are highly corrosive. DO NOT POWER WASH THE WINCH.
- Lubrication: Periodically coat exposed metal parts with light oil. Re-lubricate gearing with quality gear grease and lubricant during disassembly and cleaning.
- Cable Respooling: The cable must be respooled onto the drum under a minimum 100lb load to take the "flex" out of the line.
- Rubber Line Stopper: If included, install by fully unspooling the cable, detaching it from the drum, threading the stopper, and reattaching the cable.
Warranty Information:
- Coverage: Winches are designed for exceptional performance and durability. Warranty claims are based on the initial invoice date.
- Process: For defective contactors or winches, MotoAlliance may request evaluation or digital pictures. For Amsteel-Blue cable, a one-year warranty applies, requiring the use of an abrasion guard and avoiding sharp objects.
- Exclusions: Warranty is voided if the winch is used in applications other than self-recovery, if general care and maintenance are not performed, or if the product has been altered, misused, neglected, or improperly installed. Steel cable and roller fairleads have no warranty.
- Shipping: Customer pays for shipping to MotoAlliance; MotoAlliance pays for return shipping if the warranty covers the claim.
- Service Time: Typical service time is 3-4 weeks from receipt to return.
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