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Honda Rancher 420 Winch Installed

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  #1  
Old 04-19-2007 | 10:15 AM
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Default Honda Rancher 420 Winch Installed

Just installed a Ramsey ATV 2500 Wireless Remote unit using the KFI mount. Got both off of ebay for just over $300 total. Install was done in a little over an hour with my 6 1/2 and 5 year olds trying to help. Just follow instructions with the mount ,a minimal in trimming was required on the plastic bumper cover. Used an angle grinder with a thin metal cutting disc to trim. Don't mount the winch on the plate first then try to fit it on the bumper,it won't fit. Install the mount on the bumper first then the winch and fairlead. I left everything finger tight first then tightened everything once fitted. Then you re-install the bumper on the machine. Will be doing the wiring next. Let you know how that goes. Waiting till my optional auxilary recoil starter arrives at the dealer before I wire as the recoil kit requires removing and replacing a sub wiring harness. I want to do it all at once. Also there were no clearence issues with the winch on the bumper or with the tires at full turn.
 
  #2  
Old 04-25-2007 | 02:48 PM
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Default Honda Rancher 420 Winch Installed

Started the wiring, definetly had to do the recoil starter sub harness first. A few notes: KFI Mount instructions recommend the contactor for the winch be located behind the battery, this is really the only location for it. You also have to shorten the battery to contactor cables. I'm mounting the wireless receiver on top of the air box cover under the seat with 2 sided adhesive tape, this is about the only location I could find given the length of wire for the receiver. I had to extend the wiring for the toggle switch to make it long enough to get to the handle bars, I fabricated my own bracket to mount the switch rather than paying an extra $40 for the Ramsey rocker switch. I plan on mounting the antenna under the battery/fuse box cover behind the seat. KFI also states the winch cable should feed from the top of the spool, Ramsey says the bottom.It definetly has to feed from the top to meet the fairlead rollers properly. All in all not too difficult, there's not alot of room to mount stuff on the Rancher you have to use your imagination a bit. Have about 2 hrs into both wiring the recoil and winch, I figure I have about another hour to complete the winch job and another hour to finish the recoil starter.
 
  #3  
Old 04-30-2007 | 02:58 PM
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Default Honda Rancher 420 Winch Installed

Finally got around to completing both the winch and recoil starter. Only real advice is just follow the instructions with both the winch and recoil kit, I shortened the power cables from the battery to contactor to about 9-10 inches as that as all you need. The recoil starter went in from the right side with the body cladding removed as well as the right rear tire. An impact wrench removed the crank shaft bolt with ease, I was concerned that there was no way to hold the crankshaft while trying to remove it. When torquing the new bolt supplied with the kit you have to improvise a tool to hold the crankshaft from spinning. A "VERY LARGE" srewdriver worked set between the cut outs of the pulley and the ATV frame. Use the original bolt with a appropriate sized washer to set the seal that comes with the kit. It was very ackward to try to use a seal driver. Probably a total of about 6 hours to install both.
 
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