I have 04 Rubicon and I was planning on buying 2500 lb warn Winch. I was told it will take about 8 hrs to install so I figured it will be 2 days for me.
What is the hardest thing to do?? Or why does it take so long? I found this article that said you need to remove the headlights and front-grill first, is that right? Why?
Does anybody know where the cheapest place they found on the web? I see eBay has them around $300 but that’s with out the mounting plat.
Locally they're around $460 with everything.

 

I don't think it should take 8 hours, my situation was a little different I put on the Montana Jacks Receiver System however I believe the most difficult part is locating where to put the contactor. Some people put them in the rear storage box and I think some put them in the air box I chose to put it above the right fender behind the black panel on the side of the gas tank. It's pretty well protected and you can't see it plus it's not in the way.

 

My situation was also slightly different, since I was installing the warn multimount system (front and back receivers) and a 3K lb winch. The thing that took the longest for me was either mounting the contacter in the rear storage box or finding the live wire from the ignition switch to hook into. I recommend 2 people for finding the live wire so one can be under neath with the wire, and the other can be turning the key on and off. Buy a wiring tester that you can plunge into the wires, it save a lot of time. (Since we have the same model and year) I wish I could remember what wire I used, but can't remember for sure, maybe I'll get a chance to look tomorrow, but I want to say pink (90% sure). All in all, 8 hours should be more than OK.

For your next project, I suggest the Warn 424 selector. It slightly more difficult, but still doable and WELL worth it.

I know you have to remove the front bumper, but the headlight and grill might be something specific with your mount and not the mount I had.

Good luck

 

I did verify that the pink wire is the hot wire off the ignition on my 04 Rubi.

 

Thanks alot.........this will help me out.
Eric

 

Just a reminder to still check the wire to verify that it's hot, depending on how your dealer put the quad together when it was built it may still be a different wire.

Also, if you install both the handle bar switch and the remote switch, I ran into a little problem that could save you some extra time.

The gauge of the wire for one of my switches was (noticably) a smaller gauge than the other. Warn provides 2 wire splicers for each of these switches. Both wire splicers are the same size and (In my opinion) for the large gauge wire. I had a hard time getting a good connection when splicing the smaller gauge wire. You may have to really squeeze that wire splicer good to break the wrapping on that samller wire. Just be aware and test for conductivity before you wrap everything up.

 

Im new to the fourm and find all your information very helpful,,,thank you. I have a 2006 honda rubicon 500 and i have a warn 2500ci to install,,i was wondering if anybody would be able to tell me if i can do the install in stages, i.e. mounting the winch then wiring later on, i understand its around an 8 hour install, i work quite a bit and ride every weekend so im tryin to get it installed in pieces,any help would be much appreciated.

Does anyone now the horsepower rating of an 06 500???

 

does not take 8 hrs. i'm fairly mechanically inclined and took about 2-3 hrs. you dont have to take the front end off. basically the hardest part is routing wire to battery. just find a route close to the frame and use ties to secure it to the frame.cheapest place on the net is pats small engines.(http://www.psep.biz/)
i would consider going to 3000 lb winch. well worth the extra $ over the 2.5. it has a lifetime warranty. i had a 2.5 but with alot of use it wore out in about 2 yrs. and warranty was up! hope this helps.

 

well what i did on my rancher AT was installed the wiring first, then the mounting plate, then the winch.
it took me about 4 hours. it's realy not to hard, make sure your wires don't get close to the exaust and melt, as for the switches, i put both on mine. and spliced into the harness right next to the handlebar mount. under the plastic bezel, worked great for me. then for the remote switch i drild a hole in the bezel just above where the 12V acc plug is. just take your time and do it right the first time. you won't have problems later on. zip ties are a great thing to use. as for the contactor, i mounted it to the out side of my storage box just above the air tube thing on the right rear of my quad.. no problems as of yet it's been in water and snow for 2 years. i have the 3.0ci and LOVE it.. i plow snow and dirt and drag my and others quads out of places. enjoy, hope all goes well for you.

HR

 

Rocky Mountain ATV had the best price when I was looking and free shipping...



http://www.rockymountainatv.com/