i got my warn 2500 today and was looking at the instructions. As I orderd it through the net, I never got to see one. The only swithch it has is the remote switch. Is that the only one that comes with it? If so has anyone ever mounted a permante switch?

Also, any suggestions on the solonid location? Seem they reccomend under the seat in the rear.

Last question, Is there any special trick to mounting this? Im not worried about doing the job, I'm just wondering if anyone might have any sugestions that may make it eaiser and save me time.

thanks

 

I installed a Warn 2000 ona Sportsman last weekend. Its no problem. Just be patient while running the wiring. If it is a Polaris install kit, the wiring is pre-cut and terminated with eye type lugs. If not, be sure to use the correct wire size. If your going to buy wire, what ever size you get, (probably #6), try to locate small welding cable. Its very flexable and will be less resistive due to more finer copper conductors. Also, be sure to make good solid electrical connections. Most complaints of low winching power can be solved by cleaning and insuring good crimp connections. Everyone has seen teh car that wont start but everything else operates fine with just a loose or dirty connection at the battery. Warn recommends mounting the solenoid under the seat or in the storage department. This isn't practical on a SP500. The seat bottom is molded to take all available space, teh storage department on mine contains other things I need. I mounted mine just to the rear of the battery with the mounting nuts going through the fender under the seat. Even though Warn supplies terminal boots, I'd recommend spraying a ignition sealer type sealant on the solenoid for extra protection. For the power to actuate teh solenoid via the key switch, I spliced into the tail light circuit since its always on when teh key in on. the kit came with a toggle switch but i'm not one to go drilling holes into visible parts of the machine so I'll wait it out till I decide where to put it.

Good luck

 

I was wondering if mine would have a toggle switch ( i assume you mean a switch to give power to the winch even when the machine is on) but it did not come with any switches other than the remote.

Does anyone think it is wort installing a on off switch or just go the way it is?

 

Just pack the remote in the tool kit and plug into the receptacle when you need it. Not that difficult. You don't seriously want a big clumsy rocker switch do you? The remote is low current and controls the solenoid. You could put a neat rocker switch like the Superwinch switch as well. I believe the SW switch fails from overload.

Id look at the Polaris multi mount system while you are at it!

 

This is kinda hard to explain, regnar.

First, you don't really need the in-line solenoid; you can connect the wires to your "contactor" directly to the battery. With sensible cable routing and good insulation, the solenoid appears to me an elegant solution to a non-existent problem. I'd probably connect mine up directly and throw the in-line solenoid into the junk box.

Now, about the switch. Your remote switch provides + 12 volts to a relay in the "contactor" that powers the winch motor, switching between relays to reverse direction (out & in).

You can wire a single pole, double throw (SPDT) spring-loaded normally "off" momentary switch in parallel with your remote switch jack connections and have a fixed switch on your ATV. You can choose a rocker switch or a toggle switch at Radio Shack, for example. This switch may be compact/miniature, because the control voltage for the "contactor" is very low amperage. With this arrangement, you can use either the remote switch, or the permanent switch to operate your A2500.

The Superwinch rocker switch CAN be used as an auxiliary switch for your setup, convenient because of the handlebar mount; HOWEVER, the Superwinch switch, like the Warn rotary switch, has a shunt providing a dead short across the winch motor terminals when in the "off" position. (The shunt provides dynamic braking, we won't go there in this discussion.) Thus, you would have to provide an additional SPST switch, opening up one of the auxiliary switch winch motor legs, to use the remote switch with this hookup.

I mounted an auxiliary SPDT switch for the 8000 # Warn winch on my truck; installing a toggle switch on the "contactor" box; this winch may be operated either by the remote switch (for example, when I'm behind the wheel of the truck) or by the toggle switch, when I'm standing by the winch and its "contactor" box.

If you install an auxiliary switch for your A2500, I guess I'd wonder why you bought the A2500 instead of the A2000. The only difference between these two winches is; the A2500 has a remote switch, while the A2000 does not.

Diogenes

 

I have heard of guys scrapping the toggle switch and wire the winch direct to the battery. I have often wondered what would happen if the main Warn switch "welded" together while you were using it. It wouldn't be pretty. The new winches come with a gray rotory switch that I don't think is as good as the old syle black ones. Mine has a delay and makes a popping and crackeling noise at times. My old winch with the black switch never did that.

 

I don`t have a winch on my atv but I had one on my Suburban a Ramsey 8000#. My question is in reguards to the solenoid mounting location. I found out the hard way on my truck that the solenoids do not work under water. The winch itself worked under water but the solenoids did not they shorted out..

Would or could this happen on an atv winch? If so I think under the seat would get wet easily but I can`t think of a higher place thats practical.

98 Scrambler 500
00 Trailblazer 250
See my pic`s at http://www.picturetrail.com/riskracing

 

Some confusion arises when discussing the Warn solenoid. The in-line solenoid and its function is sometimes confused with the A2500's "contactor," called "winch power and control solenoid relays" for larger Warn winches and by other winch manufacturers.

Warn provides an in-line solenoid as a circuit protector/interruptor for both A2000 and A2500 winches, with instructions to mount the solenoid between the battery positive terminal and manual switch (A2000) or "contactor" (A2500).

This solenoid is totally unnecessary for electrical operation of the winch. The solenoid may be bypassed and the switch/"contactor" connected directly to the battery. Direct connection enables the winch to be operated whether the ignition switch is on or off, providing continuous voltage to the switch or "contactor" terminals, of concern only if this condition poses any hazard (as in possible fire or damage if the line is short-circuited when the ATV is unattended).

Now, the "contactor" of the A2500 consists actually of solenoid relays to power and to control the winch; these solenoid relays are actuated by the remote switch, connected by 3-conductor cord.

This "contactor" is analogous to the "solenoids" you mention of your Suburban, EasterEgg, in contrast to the in-line (and non-essential) in-line Warn ATV winch solenoid.

I don't know how water-resistant the in-line solenoid is; I'd probably wire the switch/"contactor" up directly if I had confidence in my winch circuit wiring.

I don't quite see how someone "bypasses" the remote switch of an A2500 and wires directly to the battery, because the contactor realys must be energized somehow for the winch to operate; if not by the remote switch, seems like some kind of switch would be required. The remote switch cannot handle the full winch current (like the A2000 manual switch), but manages the "contactor" control voltage with no problem.

Diogenes