OK here it goes. Installed an A2500 on a 2002 Grizzly. The installation was pretty straightforward but the thing won't turn. Here is what I have checked thus far. I definitely have good 12 volts to the solenoid and also to the plug. I have a voltmeter that I tested it with. Beyond that I don't know what to check to isolate the problem. I checked for power at the winch terminals by pressing the switch, putting the positive lead of my meter on a terminal and grounding the negative but I got nothing ( but I also don't know if this is a valid test). I also tried to jump the terminals on the plug (12 volts to either other pin) hoping to narrow it down to the remote switch but I got nothing. Can anyone help on troubleshooting this problem? I suspect it must be the solenoid but I don't know what to do to positively determine that. I am getting real frustrated that this is not working and if its the solenoid I will have considerable work to remove/renstall. Any help is greatly appreciated as I am about to run this thing into a tree!!!!!!

 

[img]i/expressions/face-icon-small-disgusted.gif[/img] I had the same type of problem with the 2000warn on my Rancher and it was the solenoid switch. Call warn and I'm sure the will replace it for free. There is a recall out on the soleniod switch.

 

I put a Warn A2500 on my 1993 350L about a year ago so here is what I would check. First of all I would check to make sure that the tiny red wire going to the remote control plug is indeed going to a hot wire. I spliced mine into a wire which is only hot when the ignition is on. Check to make sure that this wire is hot only when your ignition is on. Recheck all of your terminal connections; are they going to the correct terminals? Are your terminal connectors clean and tight? I don't remember if the solenoid pack itself needs to be grounded to the chassis. I mounted mine to a heavy gauge sheetmetal plate that I fabricated, so it was grounded to the chassis.
Is your solenoid pack mounted to only plastic parts? It might not be grounded? Try checking this out by attaching a small jumper wire between one of solenoid-pack mounting screws and the chassis.
If that does not cure it then it could be a defective solenoid or a bad remote control switch.
As far as the recall goes on the solenoids, I believe it only covers the solenoids for the A2000 winches and should not affect your winch.
You can check out the Warn recall information on the Warn recall banner displayed when you first sign on to the ATV connection site!

 

Frist check all your connections the grounds are just as inportant as the positive connection. It would be best if you disengaged the winch and freespooled some cable out first. Re-engage the winch and take 12v pos. power to one of the small leads from the solenoid(these are the ones that the remote switch connects to) by doing this the winch should run one way or thee other. If this fixes it check your power connection to the remote switch. If this doesn't do it then your solenoid is problably bad. You can also hook up your meter to both leads on the winch. All they to reverse the winch is to reverse the polarity on the winch motor.

 

Thanks for all of the replies..I will give them a shot tmmrw and let you all know how I make out. Merry Christmas!

 

Well here is where I stand as of today. The winch motor is definitely good (turns with jumper cables). As far as wiring it correctly, unless they messed up at the factory I did it according to the color coding painted on top of the posts on the contactor. I have tapped into the wire from the reverse limiter (tested with voltmeter to have 12 volts only when ignition is on). I also tried to string up a temp cable from the rev limiter to the plugs on the contactor (the plugs for the remote wiring) and still I get nothing. Warn is closed for the holidays but its looking alot like the contactor is bad. I dont know how that could be but I cant see it being anything else. I must say I am not happy about it either. I have wasted much too much time rigging this thing up and now I have to pull out the contactor and reinstall which is not going to be a 5 minute job. I know anything can be defective but if it dosent work out of the box I guess I have to believe they are not tested before they ship. Either way I am pretty angry. Has anyone else had problems with their Warn products? Did I make a mistake buying this thing? Anyway if there is a way to positively determine that the contactor is the problem I would love to hear how to do it. Thanks to everyone for all of the help and for now I will pray it dosent snow because the winch is the only way for me to lift my plow.

 

I had a similar problem and my winch was installed by the dealer. The problem was the switch, they tighten the bolts to tight to the front rack. I losened the 4 nuts and it worked fine. Something to try.

 

HG,
When you say the switch do you mean the large black box (contactor)? I am willing to try anything at this point but I am pretty sure the contactor on mine is spent. I am even contemplating bringing it to Sunday mass tmmrw for some divine intervention.

 

Actually mine is gray, Its the part you turn to operate the winch.

 

426,
Try a jumper wire from + on battery to one of the small wires on
the soleniod that are for the control switch. This should pull the
soleniod in and run the winch if it doesn't work your soleniod is
most likely bad.