Go Back   ATVConnection.com ATV Enthusiast Community » Brand Discussions Area » Polaris
Sign in using an external account
Register Forgot Password?
Search

Welcome to ATVConnection Forums!
Welcome to ATVConnection.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the ATVConnection Forums community today!


Reply Share this with your friends
  #1  
Old 12-30-2010, 05:37 PM
Trailblazer
Garage is empty, add now
 
Join Date: Dec 2010
Posts: 37
Default Broken Polaris Winch? Fix it yourself

my polaris 2500 winch (off a 06Sportsman 500) freespooled on me this week. After looking at some winches online and the high cost(around $200) i decided to disassemble the winch i had and see what it looks like inside. Actually found a pictoral online of dissassembling a warn winch (i beleive its from this site) and although it's a little different, there really isnt that much to it. All the gears and teeth looked fine so after a more in depth inspection, i think the problem is that one end of the shaft is rounded over a bit when i think it should be hex, like the rest of the shaft. my mission was to now find out how to order the replacement part. i found a nice parts breakdown of both the polaris 2500 and 3500 winches along with a price list for each part. I called the local dealer with each of the part numbers i wanted to replace and although they didnt have them in stock Polaris did and there shipping them to me. I couldnt beleive how cheap the internal parts are. by cheap I mean $price. For the 4 parts i ordered it came to under $10.00. The shaft was $1.99 and by the way there was no plastic gears inside. for some reason I cant post the pictures, or the parts diagram (probly because im a newby to this forum) but it can be accessed at:
http://www.polarisdealers.com/Dealer...01-2876494.pdf

The parts price list below refers to that diagram. I dont know if this will fix my winch but i'm fairly certain it will, and hopefully it will save me and some of you some money. And you may learn something at the same time. Theres nothing like fixing your own stuff.

Hopefully a moderator of this forum can place the parts diagram and price list in an appropriate place on this forum.

Good luck!
EK in CT


POLARIS 2500 LB. WINCH REPLACEMENT PARTS
Sold in single quantities unless otherwise noted.

Item
Item Code
M.S.R.P.
POLARIS 2500 LB. WINCH REPLACEMENT PARTS ASM - Motor (#1)
2876774
$79.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Coupling - Brake, Rear (#5)
2876778
$1.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Lining - Brake (#6)
2876779
$2.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Coupling - Brake, Gear (#7)
2876780
$3.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Spool (#8)
2876781
$19.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Rod - Connecting (#9) Qty: 3
2876782
$2.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Spring - Freespool (#10)
2876783
$1.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Shaft - Hex (#11)
2876784
$1.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Knob - Freespool (#12)
2876785
$2.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Clip - Spring (#13)
2876786
$1.29
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Long (#14) Qty: 6
2876787
$1.29
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Casting - Winch, FS End (#15)
2876788
$44.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Slider Freespool (#16)
2876789
$1.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gear - Bull (#17)
2876790
$1.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 3 (#18)
2876791
$14.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 2 (#19)
2876792
$14.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bracket - Support (#20) Qty: 2
2876793
$6.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Fairlead - Roller (#21)
2876794
$12.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Nut - Nylock (#22) Qty: 2
2876795
$0.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Short (#23) Qty: 2
2876796
$0.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Gearset - Planetary 1 (#24)
2876797
$9.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bushing - Spool (#25) Qty: 2
2876798
$1.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Plate - Winch Mount (#26)
2876799
$19.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bracket - Clamshell (#27)
2876800
$19.99
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Bolt - Carriage (#28) Qty: 2
2876801
$1.49
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Nut - Nylock (#29) Qty: 2
2876802
$1.29
POLARIS 2500 LB. WINCH REPLACEMENT PARTS Clip - Retainer (#30)
2876803
$0.99
Reply With Quote
  #2  
Old 12-30-2010, 05:52 PM
JCDEYO25's Avatar
Pro Rider
Garage is empty, add now
 
Join Date: Sep 2005
Posts: 1,600
Default

Nice...hope it works out for ya...

John
__________________
2005 Sportsman 700 EFI camo
800 header pipe, 800 intake
symtec winter pak
3 light mod, reverse light mod(DK)
EPI front springs
2 in. custom rear receiver
stick stoppers
Reply With Quote
  #3  
Old 12-30-2010, 06:32 PM
stendori's Avatar
Super Quad Patrol
I'm watching you!
Garage is empty, add now
 
Join Date: Jul 2003
Location: central maine
Posts: 13,786
Default

since it pretains to your polaris, it's fine posted righ on here.
__________________
02'polaris sportsman 500 "freedom"
05' polaris scrambler 500
07' yamaha vstar 1300
10' massey ferguson tractor
Reply With Quote
  #4  
Old 01-05-2011, 10:48 AM
Trailblazer
Garage is empty, add now
 
Join Date: Dec 2010
Posts: 37
Default

update to my winch repair.
I did receive a UPS box containing winch parts but only two of the 4 parts was ordered by the dealer correctly. The dealer who wont be mentioned (in Stafford, CT) ordered 2 parts from Polaris with the wrong part number, so i got parts i didn't need.

Anyways, luckily the two correctly ordered parts were the parts that fixed the winch. it was the

Slider Freespool (#16)
Gear - Bull (#17)

So in the end my winch is operational again and it cost me $14.

Not much to a winch repair, as long as you can get the correct parts, so go for it before you just buy a new one.

EK in CT
Reply With Quote
  #5  
Old 01-05-2011, 11:15 AM
lovmudd's Avatar
Pro Rider
Garage is empty, add now
 
Join Date: Nov 2008
Posts: 249
Default

Thanks for sharing. Like you said, nothing better than fixing your own stuff.
__________________
2005 Sportsman 800 EFI Camo- Winch, Glacier II 60" Razor Plow, Brushguards, Rack Extensions "Sold"
2008 Ranger RZR Red- Deluxe brushguards, 3500lb Winch, Fender flare Kit, Nerf bars, Cargo box, Hood scoop, Sport Roof, Aluminum Rims
2009 Sportsman XP850 EPS Camo- Winch, Lock and Ride frt Cargo Box, Rack Extension, Deluxe Brushguards, 27" Mudlite XTR's 66" Polaris Glacier III Poly Blow
2010 Sportsman XP550 Green - Rear Polaris lock and ride cargo box, Warn XT25 Winch
Reply With Quote
  #6  
Old 01-06-2011, 12:05 AM
readymixer169's Avatar
Of all the things I've lost in life, I think I miss my mind the most!
Garage is empty, add now
 
Join Date: Jan 2009
Location: North East IN.
Posts: 1,162
Default

Very nice. No plastic inside? Sounds like you have one of the polaris winches that were still produced by warn and you could probably find the parts from warn as well. Unlike the newer polaris winches that are made in china and are big pieces of crap. I have one of the warn made polaris winches and if for some reason it ever takes a dump and can't be repaired I'll buy a warn before purchasing one from polaris. I love polaris but it chaps my *** when they cheaped out on some parts like their winches among other things. What happened to quality and pride? OK I feel better now that I got to rant. LOL
__________________
If it aint broke, you didn't ride hard enough!
07 Stealth sp500 EFI. HO. LE.
99Yamaha PW80
07 H.D. Softail custom
2014 ram hemi crew
Reply With Quote
  #7  
Old 06-10-2013, 06:32 PM
Weekend Warrior
Garage is empty, add now
 
Join Date: Jun 2013
Posts: 2
Default

Just so people have some idea of what's going on here with these winches and how cheaply it can be resolved - here are some pictures.

When my winch started freespooling I pulled it down and couldn't identify any issues with any components (everything looked in perfect condition). Even after reading this post I was still hesitant to accept that either the shaft or bull gear were worn as they looked cleanly machined and not scored/burred as I would've expected.

The photos below show how cleanly both components wear and give little to no indication they're compromised.

New bull gear on top.
Old bull gear on bottom showing 1/4-1/2" wear on internal spline

Click the image to open in full size.

New shaft on right.
Old shaft on left showing 1/4-1/2" spline wear on the top (and some minor wear on the bottom but clearly you'd have a hard time knowing it wasn't machined like this from factory)

Click the image to open in full size.


Personally I believe this a design fault stemming from too much movement in the planetary assembly on the engagement switch side of the winch and either poor shaft engagement or the shaft not engaging completely within the bull gear. Result is obviously the spline on the shaft gradually wearing out.

However it goes - if you're mechanically inclined it's really only a 30 minute $15 fix... which is not bad all things considered.

Hope this helps anyone experiencing the same issue (and provides some clarification to this thread).

Cheers,
Windza
Reply With Quote
  #8  
Old 04-12-2014, 06:31 PM
Weekend Warrior
Garage is empty, add now
 
Join Date: Apr 2014
Posts: 1
Default

Do you have a number to where you can order winch parts?
Reply With Quote
  #9  
Old 04-12-2014, 06:49 PM
Weekend Warrior
Garage is empty, add now
 
Join Date: Jun 2013
Posts: 2
Default

Quote:
Originally Posted by natrat View Post
Do you have a number to where you can order winch parts?
natrat... GearHead.com is where I've sourced quite a few of my parts.
Mods, this is general information, NOT advertising - I have no affiliation with them but just they had ready supply and were the cheapest.
I'm not loyal to any one supplier either - definitely shop around.

Anyway, links to the parts are as follows;
Bull Gear: Polaris - 2876790 - GEAR-BULL,2500
Hex Shaft: Polaris - 2876784 - SHAFT-HEX,2500 & 3500

Total of my order was $13.73 of which $9.75 was shipping (fairly steep considering it fits in an envelope.
From memory I used a coupon code which might explain why it looks a littler pricier now.

Cheers,
Windza

Last edited by Windza; 04-12-2014 at 06:51 PM. Reason: EDIT: Deleted WordspamWordspamWordspam that magically appeared in my post???
Reply With Quote
  #10  
Old 04-12-2014, 08:18 PM
WilliamBos's Avatar
Pro Rider
Garage is empty, add now
 
Join Date: Jun 2010
Location: Innisfil, Ontario Canada
Posts: 450
Send a message via Skype™ to WilliamBos
Default

That is most likely a Warn built winch. The new Polaris winches are chinese garbage.


I love threads like this. Thanks for posting.
__________________
Thanks,

Will

2012 Sportsman 400HO
Warn RT 25, Glacier III plow.
Wish List: Polaris LED headlight kit.
Reply With Quote
Old 04-12-2014, 08:18 PM
Reply Share this with your friends

Tags
2500, 2500lb, 2876494, 2876780, 3500, brake, coupling, diagram, gear, issue, lb, parts, polaris, problems, repair, winch



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On