Im in the middle of installing a warn 2500 on my rubicon. Before I start splicing any wires could any one tell me what is the best wire to splice into and where it is located. Im talking about the wire for the control switch. Any help or tips is appreciated.
Brian

 

I'm not sure what you are referring to by your term, "control switch." The A2500 is controlled by a toggle switch on a cord that plugs into the "contactor." Do you mean an in-line solenoid relay? You must find the wire that is "hot" when you turn on your ignition switch and connect the control voltage terminal of the solenoid to that connector, if you're referring to the solenoid when you say, "control switch."

Generally, you don't "splice" into other wiring in winch installations. Instead, winch wiring runs uniquely directly from the battery to all winch systems (the exception, control voltage from the ignition circuit for the Warn in-line solenoid, if you choose to use the solenoid in your installation).

Unique winch wiring is required because of the high current (188 amps max in your case) a winch draws, more than all the other systems on your quad combined, including the starter motor.

Your wiring will go directly from the battery (through the in-line solenoid, if you decide to install the device) to the "contactor;" then, directly from the "contactor" to the winch motor terminals. (You will connect a wire, hot when the ignition switch is on, to the solenoid, if any.) Then, plug in your remote toggle switch and winch away.

Tree Farmer

 

Im looking for the wire that is "hot" from the ignition. There are 7 or 8 wires coming from the ignition and I was hoping someone could narrow it down for me and tell me which wire and what location on that wire to hook up to.
Thanks again.

Brian

 

Grab your testlight and tap into a wire that has power only when the ignition is in the "on" position.

 

Bdsomers, some users ignore the solenoid and hook their winches up direct to the battery.

If you don't mind the capability to operate the winch with the ignition switch off, and you're satisfied with the cable run and insulation between the battery and the "contactor," in my opinion, you don't need the solenoid.

Some are afraid of a "runaway" winch; I find the prospect remote and know for a fact Warn provides no in-line solenoid circuit breaker on higher-capacity winches (like the 8000 # Warn on my truck).

It's your quad; rig it up the way you want it.

Tree Farmer

 

BDSomers,

I have to agree with Tree Farmer. I just added a winch to my ATV and went directly from the battery to the winch control switch. I did not use a relay for two reasons. The first is the winch didn't come with one, the second, it's just something else to malfunction.

If you're thinking about connecting the positive power lead for the winch motor to a hot lead off the ignition, don't. The ignition wire simply won't handle the load and the current draw will do one of two things, blow a fuse or fry a wire. Either one is a bad thing. Especially since it will happen when you're stuck and really need the winch.

Richard B

 

bdsomers,

I'm pretty sure you're referring to the splice going to the solenoid from an ignition switch controlled wire. Any wire that is made hot by the activation of the key switch is fine. There is very little amp draw on this splice so there isn't really a best wire to use. All this does is activate the solenoid which allows the contact between the heavy duty battery wires. What the others said above is somewhat correct, you can bypass the solenoid and wire directly to the battery. I personally don't like that method as it leaves the winch hot at all times. I'm not worried about a runaway winch, but I like everything to go off when I turn the key off, that way I know my battery won't be discharged when I come back. I'd highly recommend going by the instructions and using the solenoid, it doesn't hurt anything and might save you from being stranded one day. As I said above, any wire that becomes hot with the turn of the key will do, just pick the one that's in the most convenient location.

 

Not to argue, Hunter32, but everything doesn't go dead when you turn off the ignition switch on your quad. For example, the heavy-gauge "hot" wire between your battery and your starter solenoid is "live" at all times.

This situation is parallel to bdsomers' Warn A2500 winch setup; if he eliminates the solenoid in his circuit, the wire to the "contactor" will be live at all times. However, unless bdsomers plugs in his remote winch control switch, the "contactor" will never activate the winch, nor will any current be drawn when the quad is unattended.

Is there a risk of short-circuit (and possible fire or damage) from this live conductor? Yes, but not significantly greater in my view than the risk of a live conductor to the starter solenoid, a situation present on virtually all electric-start machines.

Nevertheless, if someone wants the winch circuit disabled when the ignition key is off, the Warn solenoid works fine for that purpose, providing an extra measure of safety, and offering a means to shut down the winch in case of a control switch malfunction. To each his own.

Tree Farmer

 

The reason I like my winch off, with the ignition off, is because atv's draws kids like a magnet. I don't want the possiblity of them getting hurt. Bdsomers, if you have'nt found the ignition wire yet, when I get home this evening I'll look at mine, and post it tonight.

 

I spliced into the pink wire at the key ignition.