Polaris SPORTSMAN PRO HD 2882242 Bedienungsanleitung

APPLICATION

Verify accessory fitment at Polaris.com.

BEFORE YOU BEGIN

Read these instructions and check to be sure all parts and tools are accounted for.

Please retain these installation instructions for future reference and parts ordering

information.

KIT CONTENTS

This Kit includes:

REF QTY PART DESCRIPTION PART NUMBER

1 1 Handlebar Switch 2205636

2 1 Control Box 2413444

3 1 Wireless Remote Kit 2879316

4* 5Cable Ties, Nylon -

5* 4Screw, Hex Flange - M8 X 1.25 X 25 -

6 1 Mounting Bracket 1022577

7 1 Winch - 3500 HDDS 2206383

8 1 Hook, Winch Latch 2411836

Instr 9927475 Rev 01 2017-02 Page 1 of 14

P/N 2882242

SPORTSMAN®POLARIS®PRO HD WINCH

KIT

Instr 9927475 Rev 01 2017-02 Page 2 of 14

REF QTY PART DESCRIPTION PART NUMBER

9 1 Rope 2878888

10 1 Winch Cable, Yellow 6 GA (mm) 4013468-300

11 1 Winch Cable, Blue 6 GA (mm) 4013469-300

12 1 Power Cable, Black #6 (mm) 4013470-530

13 1 Power Cable, Red #6 (mm) 4013471-510 WC

14 1 Contactor 4015095

15 1 Autostop Fairlead 5140385

16 1 Stop Magnet 5415787

17 4 Screw Torx®Head - M8 X 1.25 X 20 -

18* 2 Screw - M6 X 1.0 X 25 -

19* 2 Screw - M10 X 1.5 X 25 -

20* 2 Nut - M10 X 1.5 -

1 Winching Guide 9923644

1 Instructions 9927475

Service Handle (includes freespool handle and screw) 2205265

Items marked (*) are included in Hardware Kit (PN 2880643).

TOOLS REQUIRED

• Safety Glasses

• Socket Set, Metric

• Screwdriver, Phillips

• Wire Cutter

• Hex Key Set, Metric

• Socket Set, Torx®Bit

IMPORTANT

Your SPORTSMAN®POLARIS®PRO HD WINCH KIT is exclusively designed for your vehicle. Please read the

installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of

debris. For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the

sequence shown.

ASSEMBLY TIME

Approximately 40 minutes

Instr 9927475 Rev 01 2017-02 Page 3 of 14

INSTALLATION INSTRUCTIONS

NOTE

This kit contains the same components as

Sportsman (XP) winch kit (PN 2882241), but have

been pre-assembled differently. If you need to install

this kit on a Sportsman (XP) vehicle, refer to image

below that shows the contactor location and wire

routing for Sportsman (XP) winch kit, and

reassemble the contactor and wiring to match below

image. You will need to download instructions

manual (PN 9927474) and follow those instructions

for final installation.

* ABOVE IMAGE REFERS TO KIT PN 2882241

PREPARATION

1. Place vehicle in “PARK”. Turn key to “OFF”

position and remove from vehicle.

2. Detach the rubber latch Bon both sides to open

front rack A.

3. Open the front rack Aand remove rubber seal C.

4. Remove four screws Dholding front cover Ein

place. Retain the screws Dfor reinstallation.

Instr 9927475 Rev 01 2017-02 Page 4 of 14

5. Lift the front cover Eupwards slowly to disengage

the tabs on front cover from the slots Fas shown.

6. Disconnect black (negative) and red (positive)

cables from battery.

WARNING

ALWAYS disconnect black negative (-) cable from

battery FIRST. Failure to do so will result in high

current electrical arc, and may result in battery

explosion if tool touches grounded frame. Death or

serious personal injury may occur.

7. Disconnect the black (negative) Hand red

(positive) Gcables from the bus bar.

8. Remove the accessory front brushguard from

vehicle (if equipped).

9. Remove lower front bumper cover Jfrom vehicle

by removing four bolts Kas shown. Retain bolts

for use during reinstallation.

10.Remove winch cover Lfrom the lower front

bumper cover J. If you plan to use a plow, remove

winch cover from the lower front bumper cover J

and do not reinstall. If you do not plan to use a

plow on your vehicle, cut out the center section as

shown and reinstall winch cover on the lower front

bumper cover if you desire, but it is not required.

Instr 9927475 Rev 01 2017-02 Page 5 of 14

NOTE

Before installing the winch kit add or replace the

proper fluid to your front gearcase as required per

your vehicles service manual as this process will be

difficult to do after the winch is installed.

WINCH INSTALLATION

NOTE

See the Electrical Connections Reference Guide

section of the instruction manual for detailed photos

of each part and their respective connections.

1. Check and confirm wire routing and connections

are as shown below and make necessary

adjustment before moving to next installation

steps.

NOTE

If you have a Utility model, the brackets supporting

the front steel bumper will interfere with the blue and

yellow wires in the stock configuration as seen

above. You will need to loosen the nuts holding the

blue and yellow wires to the contactor, rotate them

as shown below, and then re-tighten the nuts. Refer

to image below for proper routing.

2. Locate white contactor connection Mon winch

assembly. If it is secured to the winch assembly

with a plastic tie, cut the tie to allow the wires to be

routed properly.

3. Install winch assembly uonto the radiator mount

Nwith the supplied four screws t. Check that all

wires are free to move and not pinched between

the vehicle chassis and the winch assembly.

Torque screws to below specification.

TORQUE

20 ft. lbs. (27.1 Nm)

Instr 9927475 Rev 01 2017-02 Page 6 of 14

4. Route red (positive) fand black (negative) d

winch cables on the side of the radiator then

behind it to reach the three terminal bus bar as

shown. DO NOT CONNECT TO THE WINCH

CABLES TO THE BUS BAR AT THIS TIME.

CONTROL BOX INSTALLATION

1. Position control box won the right side of the

vehicle behind the radiator as seen in the photo

below. Connect white electrical connectors for the

control box as seen in the top photo of the

Electrical Connections Reference Guide section of

the instruction manual.

2. Route power wires to battery area and connect red

or orange wire from control box to orange wire on

the vehicle’s main wire harness as seen below.

Route black wires from control box wto black

(ground) terminal area near the bus bar. DO NOT

CONNECT TO THE BUS BAR AT THIS TIME.

WIRELESS REMOTE RECEIVER INSTALLATION

1. Install wireless remote box eonto cab support

bracket Qusing cable ties as shown.

Instr 9927475 Rev 01 2017-02 Page 7 of 14

2. Connect white electrical connectors as seen in the

top photo of the Electrical Connections Reference

Guide. Route power wires to battery area and

connect red or orange wire on control box to

orange wire on vehicle main wire harness as seen

below. Route black wires from control box wto

black (ground) terminal area on bus bar.

3. Now connect the red Gand black Hwires to the

bus bar terminals along with winch power cables

f d using existing fastenersP

. Also, connect

black wires on the wireless remote receiver box e

and control box wto battery negative (ground)

terminal at this time.

4. Secure all remaining wires to vehicle main wire

harness using cable ties as shown.

HANDLEBAR SWITCH INSTALLATION

1. Install the handlebar switch qusing the supplied

screws Ponto handlebar as shown. Torque

screws to the specification listed below being

careful not to overtighten.

TORQUE

2 ft. lbs. (2.7 Nm)

2. Connect handlebar switch connector Sto the

vehicle main wire harness as shown.

Instr 9927475 Rev 01 2017-02 Page 8 of 14

WIRELESS REMOTE HOLDER INSTALLATION

1. Wireless remote holder can be installed in desired

location on vehicle. Use the screws provided in the

wireless remote kit for holder installation. For your

reference see the photo below for possible

mounting location of wireless remote holder.

FINAL INSPECTION

1. Confirm that all wiring is correct.

2. Confirm that there are no exposed wires or

terminals.

3. All loose wires need to be wrapped tight, and

secured away from moving parts and heat

sources.

REINSTALLATION

1. Reinstall the lower front bumper cover J. If you

plan to use a plow, do not reinstall winch cover L.

If you do not plan to use a plow, reinstall winch

cover L.

2. Reinstall accessory front brushguard (if equipped).

3. Reconnect battery red (positive) and black

(negative) cables to battery terminals at this time.

4. Reinstall the front cover Eusing retained

screws D.

5. Close the front rack Aand secure in place using

rubber latches B.

6. With the vehicle key in the ON position, check

winch for proper operation.

Test function of Autostop feature. When reeling in

the winch rope, confirm that the winch will turn off

automatically when the rubber puck reaches the

aluminum fairlead. The winch should not allow the

rope to be reeled in once the rubber puck has

come within a close proximity (typically 1” or less)

or made contact to the fairlead. If the Autostop is

not functioning properly, see troubleshooting

information at the end of the instructions.

Instr 9927475 Rev 01 2017-02 Page 9 of 14

HANDLEBAR SWITCH OPERATION

• When properly installed, the handlebar switch

allows you to operate the winch while seated on the

vehicle. See the illustration below for proper switch

operation.

WIRELESS REMOTE OPERATION

• When properly installed, the wireless remote will

allow you to operate the winch from off the vehicle,

which can be a safe way to operate the winch when

done properly.

• To use the wireless remote, hold the small "On/Off"

button for three seconds or until the LED light on the

remote turns on. If the vehicle is on so that the

winch is receiving power, the wireless remote

should operate the winch as if you were using the

winch switch qlocated on the handlebar. If the

remote is not operating properly, see the

troubleshooting information at the end of the

instructions.

• The remote will automatically turn itself off after 30

seconds of inactivity. You will therefore need to turn

the remote back on if it has been more than 30

seconds since prior use.

• To manually turn off the remote, hold the small "On/

Off" button for 3 seconds or until the LED light turns

off.

• See the illustration below for proper wireless remote

operation.

Instr 9927475 Rev 01 2017-02 Page 10 of 14

AUTOSTOP OPERATION

The Autostop system is meant to help prevent

damage to the winch system from over-tightening of

the rope, but is not meant to prevent all foreseeable

winch damage. The winch is very powerful and care

should be exercised whenever it is in operation. The

winch operator is always responsible for using the

winch properly and the Autostop system should only

be used as a secondary preventive measure to help

prevent damage to the winch from over-tightening the

rope.

The Autostop system works when the black rubber

puck nears the aluminum fairlead h. Stop magnets j

in the puck trigger sensors in the fairlead, which

prevent the contactor from pulling in the winch rope

any further.

During final inspection, confirm that the Autostop is

functioning properly. Troubleshooting steps are given

in that section to help diagnose and correct any

problems.

GEAR SELECTION

WARNING

Attempting to shift the winch while the rope is under

tension is dangerous and can result in injuries or

death. Make sure the winch rope is not in tension

before shifting the winch between gears.

Your winch is equipped with three different gear

settings. High, Neutral and Low. When in neutral the

“N” marking will show thru the cutout window on the

shift knob. See photo below.

The high gear setting is meant for rapid recovery

mode only and should not be used while the rope is

under load. To shift into high gear, rotate the gear

shifting knob clockwise until the “H” marking shows

thru the cutout window on the shift knob. See photo

below.

NOTE

High gear is for rapid recovery of the winch rope

only. It is not intended for pulling and will reduce the

life of the winch if used under load.

To shift into low, rotate the gear shifting knob counter-

clockwise until the “L” marking shows thru the cutout

window on the shift knob. See photo below.

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