Ok heres what i would check out, unless i missed something, go across both connectors rite at the motor itself with a volts meter. Operate the switch and look and see what it does, you should have 12 volts or - 12 volts depending which way you went with the switch. If i had to guess Id be reeally lookin hard at the Main ground. I know what it feels like to look like an *** cause i over looked something really simple. Im very familar with the warn line of winches and i havent seen any thing to date that came from the factory bad cept the solinods, not to say that the contactor is bad im just trying to help ya here bro. Before you take it in make double sure everything looks just like its supposed to be and dont over look the obvious. Btw the boot the fits over the lug on the bottom of the winch holds water, i had to snip a hole in mine and i also greased the nut really good cause i found mine rusted to hell, anyways good luck on your prob and keep us informed on your progress, Later , Rob

 

Rob,

I put a voltmeter on the + and - terminals on the contactor and got a solid 12v. I even took it a few steps further by jumping directly to the winch and it spun fine so the motor is definitely good. In an effort to further diagnose I took a good 12v lead and connected directly to one of the pigtails on the contactor and I got nothing, not even a click ( I would imagine you would definitely hear a click). I tested from the red terminal on the contactor to the frame with a voltmeter and also got a good 12v. I don't know if a loose ground would cause that but I guess it might. I have seen it on my car so maybe I had better check before I make a mojor fuss with Warn tmmrw. Thanks

 

You couldnt imangine the prob you could have with a bad or loose ground. If the contactor isnt clicking the its not gonna work. If you can bypass the switch and run a hot and negetive rite to the contactor from the battery. At least find out if the contactor will switch back and fourth. Sorry just my 2 cents worth.

 

Well everyone I have to tell you Warn is a first class operation. I called the service number this morning and spoke to one of their techs. I explained all of the troubleshooting that I had done and he said "it seems like you have a bad contactor, I am very sorry for any inconvienience I will ship a replacement overnight. You should have it on Thursday." Needless to say I was very pleased. I did tell him about my unpleasant experience with their authorized service center. He was very sympathetic again apologized for all of the trouble I had been through and all of the time I had spent trying to make this work. They have definitely won me over as a customer. This is exactly what separates the great companies from the rest. Thanks to all who have helped me troubleshoot this as I feel the tech heard that my troubleshooting was methodical and left no stone unturned (once again thanks to you guys). I will let you all know how I make out with the replacement once I get it installed on Saturday.

 

I don't know if you fixed your winch problem but i had the same one.In the directions it calls for three (3) star washers under the terminal pin sticking out of the mounting plate,they are VERY important,without all of them OR overtightening them will cause them to not make contact. Check out your setup and see if they are all there, if so, add another to each post... it should work for you too , good luck

 

Actually got it working. It was a bad contactor. Guess I was the only one to have this problem..oh well its just my luck! Hopefully others can benefit from all of the info in this post as well. Thanks again!

 

Hi,

This might sound stupid but I had the same problem. The problem was resolved when I connected the red (about 18ga red wire)that connects to the socket for the remote to a hot lead. The winch worked perfectedly. It is designed to connect this red lead to the key swithch of you atv so the winch will only operate with the key on.

I couldn't tell from your writeup whether or not you tried this.

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