I bought the warn winch kit for my 06 500 sportsman and I cannot figure out how to install the contactor. I know where it goes and how it should be installed; the prewired wires on my ATV do not match up with the contactor block.

The prewired wires on the ATV (red and black) have a large plastic block on the end of them holding them together. I do not think I need to remove that plastic block b/c the wires are configured to fit into the necessary grooves of the contactor.

I have looked at other contactors online and they look exactly as mine does so it may be how the wires are connected or do i need to remove that large plastic block to make them fit on the contactor?

Any help is greatly appreciated.

Thanks

Scott

 

go to my pics - does the contactor look like mine? (it's a blurey picture but you can make it out). if so - you need to split the the 2 wires - the black block in half (i used a dremel tool) and you need to mount the contactor to the frame - not the angle bracket.

 

The contactor in your picture is the old style contactor. Warn recalled those contactors because some of them were melting or something. The new contactor is color coded and some of the wires are prerun through the ATV (red and black).

the blue and yellow wires are connected to the winch. the way the red and black wires are connected (through the plastic boot) should allow them to slip right on to the contactor but I think my contactor is designed differently.

I have the winch install directions from polaris and they say that I don't need to cut away that hard plastic boot between the red and black wires. Although, if i did do that I could probably make it work....

 

http://warn.com/atv/recall_notice.shtml

No- this is the one recalled - my contactor came with a brand new XT25 - sealed box 2 months ago. the recalled are 8 post - mine is a 4 post. Mine is also color coded

 

which winch did you get from warn. the one that brutus has is the newest style i do beleave.

 

i had the same problem with my rt30 winch and my 06 500.
i split the factory harness with a pair of wire cutters and then i used the short red and black wires that came with the winch, (i used colored tape to mark them yellow and blue on both ends), i used these from the contractor to the winch..

 

I bought the warn winch kit for polaris from my dealer; not the RT OR XT setup. This winch bolts directly to the front of the frame of the ATV. you don't need the mounting bracket to mount it to the ATV. It is the winch that comes with ATV from the dealer; not the aftermarket warn winch.

My contactor is color coded and has four connectors (red, black - prewired on ATV, blue and yellow - from the winch). I can make it work if I cut the plastic boot holding the red/black wires together, but I didn't want to start cutting stuff on my ATV if i didn't have to.

Also, this contactor mounts directly to the splash shield quite easily; I am not sure why you had to mount yours to the frame.

 

you said you didnt buy the warn winch? is yours a wrinkle finshing. the contacter that brutus has is the newest style for the xt30 vs. my older 3.0ci warn. these you need to have the bracket to bolt to the wheeler.

 

polaris has alot of differant styles of contactors the one you have has got a plastic set of walls seperating the red & black posts on the contactor as well as seperating the blue & yellow from the red & black . its an older winch setup that the dealer probably had in stock , the contactor your looking for only seperates the blue & yellow (no L shaped wall between red & black ) just go back to the dealer & tell them you have the wrong contactor , they should exchange it !

 

sooooooo ORKISS....................did you get it done?