So yesterday I finally got my winch for my Outlander Max. I spent 4 hours installing the little bugger on my ATV. The install process was a little time consuming, but I wanted to make sure that I did it right and made it look professional. It looks sweet. If you don't have a winch, the look is ALMOST worth the price.

Anyway, my question is, how do you make sure the winch spools properly. I could not for the life of me get the thing to spool back properly under load even with the line directly in front of me. I had to hold the line and manually wrap it up properly so that it wouldn't bind. Just wondering if there is a good technique out there for it.

Matt

 

Matt,

I'm currently installing a 2.5ci w/ roller fairlead on my OutMax 400, so once I'm done I'll give the spooling a try and let you know how it went. In the meantime, can you tell me where you mounted the contactor? I've looked all over and I can't find anywhere obvious. I'd like to put it in the same place they do at the factory, if possible.

James

 

Hey James,

This was fun to figure this out. There are a number of places that you can install this, but you need to keep this in mind.

- Keep it close to battery
- Keep it in a place that doesn't get "constant" water (i.e. under wheel wells)
- Make sure to run your wires tight and not near any sharp areas.

The first two were easy. The last wasn't all that simple. I had to run the main wires to the winch through the frame with the other electrical wires. They are well protected in there and they don't have any sharp edges to cut through the wires. My biggest hint for you is spend some time planning the whole thing out. It will be a HUGE benefit to you. My installation looks as pro as they get, and I have never done this before. Sorry, I deserve bragging rights. =)

As for the contractor, I called both Warn and Bombardier and asked them where to place this. They both said right below the storage box on the rear would be a great place. They also said that I could install it in the storage box. I chose the outside location because I was worried about the exposed portion of the contractor coming in contact with something metal. I can take pictures of it if you would like me to?

Also, I took the ATV into the dealer to get the spedometer replaced and they said the install looked great and that I wouldn't have any problems, so that was conforting.

Let me know if you have any other questions. I did a lot of research and it really paid off. We have already used it a few times to pull other people out and move some trees, so it is definitely worth the $$ and the extra care on the install.

Matt

 

Matt,

Where did you bring the cables out at the front? I looked at taking them down the spar yesterday but it looked like a tight fit (under the air intake, where the other cables go in). I also thought about bringing them out of the spar just forward of the steering shaft, but the edges felt pretty sharp. Regarding the contactor, I'm thinking of putting it under the seat, attached to the frame that the back seat rests on.

james

 

James,

You are correct about it being a tight fit to get those wires through the spar, but it is worth the effort. You will want to drop the wires out below the intake. I pushed them through the front and didn't like the way I had to bend the wires so that is why I chose the spar route. I fished the wires through by connecting a small rope (about half the width of the 6 guage wire) to one of the wires and pushed it through (actually I got some help from my wife). I then used a hanger with a small hook to pull the first wire down through the hole in the spar below the intake. I then tied the end of the rope I pulled through with the other wire to the top of the second wire.... here is where my wording might get tricky... I also tied another piece of rope to the top of the second wire so when I fished the second one through, I had a piece of rope that was coming through. I then took the switch wire and tied that on to the rope and carefully worked that backwards through the spar to the contractor. Now I had three wires successfully fished through. This took some planning and some patience, but like I said, it looks great!

One note here. I already had everything attached to the ATV at this time. Make sure that you have the switch hooked up to your handlebars or you will be very sore when you have to pull the wire back out of the spar to get the wires in the correct place. You will also want to have the winch and contractor mounted.

Your placement for the contractor should be fine, just make sure that no metal would hit it in the roughest of conditions. It will most likely start a fire which isn't a good place under your butt. =) You will just want to make sure that the red & black wires reach your location from the battery. Actually just the red, the black can be grounded anywhere to the frame. I hooked the red to my solenoid so that I could disconnect the battery just as easy as normal. liked the placement of mine because it extended the wires fully so I didn't have to find a place for the excess wire. I also have the Max, so the extra length helped.

Matt

 

Matt,

All went well yesterday. I pulled all the wires through the spar and attached the contactor under the storage box (not quite enough room under the seat). I coiled the excess at the front end of the spar and even tucked the excess black and red wires into the back end of the spar. Everything is nice and tight. Hopefully it's far enough center that I won't sling any wet mud on it.

BTW, how did you mount your switch? I am planning on attaching a Ram-mount plate to the threaded socket to hold my GPS and I thought I'd attach the switch to that plate. Speaking of the socket, do you know what the threading is? I'm assuming it's metric since I have nothing that will thread into it.

I'll get a chance to try out the winch this Friday. I've got a buddy who can't seem to make it though the puddles I do and I'm always pulling him out.

james

 

I mounted my switch on the left handlebar to the left of the brake. It fits perfectly. I have the mini rocker switch.

As for the threading, I assume it is metric since those were the tightest fit.

Congrats on the install. It is nice to be able to look at your accomplishment and say "I did that!".

Matt