Hello fellows I have the round bumpers on my machine while installing the warn 2000 winch it is such a tight fit I had to cut a little bit off of the one of the bolts that hold the cables on the winch due to it rubbing the outer cover of the radiator mount and it still touched so I had to place a rubber insert on the bolt after installing the cable if you do not do this you will short out the winch when trying to pull in the cable on it...has anyone else had this trouble with the tight fit...

 

Ya I had the same tight fit. My tube bumper is leaning on the back garage wall for 1 1/2 years, thats how I delt with it. Guess I will have to deal with it someday.

 

No, I haven't noticed that, but I am having a problem mounting hte control switch on the rack. It seems as though the U-bolts are too short and won't make it around the composite material of the rack and through the switch. How very irritating, now I've got to make a trip to the hardware store to buy something Polaris should have known better about in the first place! Arrgh!

 

ATVing,

Man your posts would be a whole lot easier to read and understand if you would use some punctuation. I think this one is 6 sentences all run into one!! Slow 'er down. Capital letter - type - period - breath - 2 spaces - capital letter - type again - and so on.

Hav'in some fun with ya, but it really is hard to read ...

There was just a discussion on this very topic a day or two ago.

DJ

 

Thats another thing Y2K you definetly have to go out and buy longer U bolts the original ones won't fit around the rack. But it is definetly a tight fit chopper be sure when you do install to either rubber coat or put a piece of rubber around the bolt that touches the radiator cover or the winch will short out. Or either cut out a small piece of the radiator cover...

 

Have the wench mounted just havent put on the bumper. I mounted the switch on the left fender, with 4 carraige bolts, right behind the rack. Didnt want to use up rack space.

 

I have the round bumpers and used the mounting plate made for this bumper and had no problem. (Warn now specifies on the winch box if it is for the round bumpers and includes the mounting plate). The only tight fit I had was the mounting plate bolt on the right side was hard to start because of space, but no other problem.

I mounted my switch on the side the tank area so it is easilly accessible while using the throttle and steering - as some of you suggested.

 

Did the same here tear the winch apart you con turn it so the bolts wont hit.

 

I have no problem with the wires but had a BIG problem accessing the "engagement" lever on the right side because of the very limited opening on the bumper winch bracket. I cut a good 1.5x4 inches in the bumper, enough to have a good grip on the lever and to keep the bumper strenght. Winching was really a pain before...

Did you also noticed that using the normal springs with the bumber and the winch was also an error? I measured 9.5 inches at rest between the floor and the skid plate with this setup. I am now installing heavy duty springs to go back to the 11+ inches of ground clearance.

 

I don't know if your mounting is the same as mine ,I too have the dual tube bumper ,but the dealer had to cut a 2.5"hole(?) on the side where the locking mechanisim is located to engage or free spool the winch. hope the helps.It's very aggervating to install , I had the dealer install mine for $150.00 . Very well worth it, would have done it myself but no time to install.