I have a 2000 Sportsman 500 I bought a warn/polaris winch kit # 2871775 and frt bumper #2872037. My problem is I can't get them both to align at the same time either will fit the bike alone but not together, the problem is where the cable pass through the winch mount ,that bracket hit the bumper when i try to put it on and pushes it away from the mounting holes....HELP PLease I want both on my Polaris.. Email JKirkpa883@aol.com

 

Hello Jkirk it is a really tight fit I know, the best thing I can tell you to do is to put it up there and bolt both pieces on to one side and then press the opposite side till you can get the bolts to start when you get them started then unloosen the other side a little bit till you can get the other side to tighten up if yours was like mine it looks like the lips need bent in more what ways are you having trouble with it fitting up mine was so tight I had to cut a piece of one of the bolts off the winch where the negative or the positive was to get it to fit...YES IT IS A TIGHT FIT anyway I can help just email me...

 

I just sent you an email about this. It sounds like you have the twin tube bumper. I bought my winch before the bumper. Now I have an extra mount because I got gouged by Polaris to buy the mounting plate for the bumper. It cost me about $90. I tried to use the first mount I had but it hit the top tube. I cut off the fairlead mount and the winch sat to high for the bumper and the cable was at an awful angle always rubbing the roller. I had the exact same headaches you are having now. Here is a tip go buy the mount for the twin tube bumpers and use the bolts that came with your first mount. They are much better than the crap that came with bumpers.

 

Mds I had one of the original winch mounts to but my dealer was nice enough to exchange it for the one that came with the bumper, which I didn't install but I thought that was pretty nice if I am not mistaken can't you take a torch and do some cutting on it to make it fit...by the way Mds how do you like your Sportsman what color is yours...man I wish I would have waited and bought the Rubicon...yeah right hehehe and don't any of you Honda guys get your panties in a bunch its just a joke but I really can't wait to meet up with one on the trails I would like to see if the Ruby can hold a light to the Sportsman.

 

I'm getting a kick outa this thread. I just did my new Xplorer last night. It wasn't a fun job. The instructions SUCK! I hung the bumper on and had the top two bolts on each side screwed in just a few threads. Then I slid the winch up into it's location with it already mounted on it's bracket. Slid the bolts in to hold it in place and spun the nuts on. Then I installed the 6 side screws for the shroud by hand. Then, I tightened the top two bolts on each side of the bumper, tightened the winch bolts then tightened the screws. FWIW, I installed the solonoid on the firewall right behind the oil tank under the "hood". The switch is on the LS of the front rack towards the rear of the quad. I have about 4 hours in it so far and still need to do the wire tieing and testing. I wanna go riding!!! I've put a whopping .2 miles on it so far.

 

Oh, one more thing. Make sure install the wire onto the top terminal of the winch before you stick it in there. It's a bitch to get to afterward.

 

I think I found the best solution to this problem. Don't be cheap when purchasing a new quad. Buy the winch and bumper with your new ATV and have the dealer go through the head aches of installation. I love my SP 500 with a WARN 2000 on the front. Its already pulled out two hondas and its only 5 days old. I really love to see a 4x4 honda man grit his teeth to see my big yellow Polaris ****** them out of a mud hole I just went through. Ride on!!

 

ATVING,

I cut the fairlead mount to make it fit. It worked all right but the cable was always rubbing in the fairlead. It looked like a pretty harsh angle. The biggest problem was trying to get your fingers in there to freespool and engage the clutch on the winch.

I had a WR400F Yamaha on order at the dealership for about year. I was waiting for the new 2000 model. The weather started getting warm and I started getting the itch to go ride. Walked in to check on the status of the bike and bought a red Sportsman instead. They had a yellow one on the floor and it had a sold tag. Have you ever tried to jump the Sportsman. I have problem keeping my feet on the machine and when it hits there are two craters from the rear tires.

 

I have a 99 magmun, I have the tube bumpers and a 2500# warn on the front. I helped the dealer put the winch on. What we did was grind the front of the winch mounting bracket off, the part that turned up, and then just bolted both of them up. I was not easy getting all of the holes to line up, but the look in the end is worth it. Also it is difficult to get to the free spool end. Since I put the mud runners on I don't have to use the winch as much. See ya, Jonathan

 

THanks alot guys for all the help, I did what many of you said I cut the fairlee attachment off the front of the winch mount and grouid it down flush, after noticeing that the cable would have rested on the fairlee continuiously I decided to drop the bumper down about 2" by drilling the side of the winch mount and putting a couple of bolts in it then I redrilled the rear bolt holes on the bumper ( where it attaches to the Radiator shroud) I was able to match up 4 of the 6 1/4" bolts, turned out very solid and I can easily get to the free spool on the winch, over the top of the bumper. Time to wire it up now.... Thanks for he help Jim <><