I tried to install a 2500 warn winch yesterday onto my 2006 800. The 2006 is prewired with the 6ga wires terminating at the Front RH side of the ATV. But the two wires, (HOT and Ground) are molded together with a plastic separator that keeps them a certain distance apart. When I tried to connect them to the contactor (# 62135) I couldn't make it work. The posts on the contactor were color coded and It looked I might have been able to make it work if I put the ground on the red post and hot wire on the black post (reversed them) but I thought that was probably a pretty bad idea.

Am I missing something? Am I suppoed to split the plastic separator apart? Do I have the right contactor for my machine? Can anyone send me a picture of their wires connected to the contactor?

 

I am guessing that you do not have a Polaris/Warn winch kit. I didn't either. I called Warn when I ran into the same problem and was told that I would have to use the traditional installation. For some reason the guy voluntarily made the point to tell me that the contactor was water resistant and not waterproof. I wanted to use the prewire so I used the Dremel and cut the wall out that was in the way. This exposed the inards of the contactor so I sealed it with epoxy making sure to leave enough room for the prewire plug. I then sealed all of the other seams, screws, and posts and submersion tested it before I put it on. After I attached the cables, I coated all of the connections with liquid electrical tape. It has been getting worked pretty hard and has been submerged a couple of times and it has taken it pretty well. I used the red and black cables from the winch to the contactor and had the blue and yellow cables as spare parts when I was done. I hope this helps.

 

I bought the Polaris Warn 3.0 kit from a Polaris dealer and had the same problem. I took a hack saw blade and split the black plastic piece which seperated the wires. So far this has worked fine with no problems what so ever.

 

i had the same problem as well. Polaris doesn't think of aftermarket parts when the make their machines. I bought a Warn 3.0 winch and wanted the multi-mount so I had to buy them separate. I used some machine bolts and the black and red wires that come with the winch. I connected the supplied wires to the prewired set on the machine with the machine bolts. I then soaked them in dielectric grease and wrapped them up in electrical tape. That way I didn't have to modifiy the factory wires or the contactor. Use dielectric grease on everything electrical if you are worried about water. I had a quad that wouldn't start then I put dielectric grease on every cable and never had a problem again.

 

I have also seperated the factory wires.... not to hard... and seems to work fine!
I was informed the relays are waterproof... but not submersible....

 

i bought the 3.0 from the ploaris dealer and didnt have too much problem installing it and pulling the wires apart to hook them up. whinch works goods so far.