This mod shows the installation of a Warn winch and wireless remote onto a 2012 Kawasaki Teryx 2012 LE SGE. Not a difficult task but figuring out HOW to perform the wiring itself was very time consuming, especially if you have never done it before as was my situation. The whole process took me several hours.
Some ideas were stolen from the Viper winch install thread by Polaris425 so thanks for that, but this one is for a Warn.
This is the short version of the install, for a complete install with pictures see my personal Teryx web site page HERE: http://mattsnook.com/utv/winch/index.htm
These 3 products are installed:
* Warn ProVantage 3500-S winch, with a wired "handlebar" switch
* Warn Wireless Control Kit (P/N 74500) - the wireless remote control kit
* MotoAlliance Winch Mount (P/N MA11933) - this is the winch mount plate itself. (I picked this brand because I am also going to install the MotoAlliance snowplow next).
Note: The first 2 items were specially bundled so I could get the Wireless remote and it may be that normally the 3500-S winch comes with a removable wired remote with a connector that you mount and then plug in the wired remote when needed.
When I purchased it the Warn XT line was being phased out in favor of the ProVantage line, and in my case the 3500-S was an "early product package" so I did not get this wired remote (and didn't want it). So be sure you know what you are ordering as my bundled items here may be different!
I purchased these 3 items from Matthew at ATVOutfitters.net who bundled them for a great price. I learned about them on this forum and I highly recommend them as well, both for pricing and great product knowledge and advice. They rock!
I'm new to ATV's and UTV's, coming from the motorcycle world, but since I got a lot of help on this forum I'm now giving back!
This thread will include wiring diagrams and pictures of some of the installation steps.
Decide where to mount the Contactor:
Your first choice now is where to mount the contactor. The contactor goes in the path between the winch and the battery and acts like a relay to switch the high current.
I decided to mount it right on the firewall under the hood.
The key is that they provide a short pair and a long pair of fat cables and unless you want to make new ones you have to check to see that they will reach for wherever you decide to install the contactor.
The directions have you mount the contactor tucked in by the battery attached with short cables and then run long cables to the front to the winch.
But since I decided to mount it on the firewall it is now closer to the winch so you use the short cables to the winch and run the long cables to the battery.
Here are a couple of key diagrams with notes, which shows some of the key changes to directions that I did, mainly swapping the pairs of cables and their new colors.
Since I mounted the contactor on the firewall under the hood, the Warn cable pairs are swapped. In these diagrams you will see that NOW you use the shorter Red (+) and Black (-) wires to the winch, and the longer Yellow (+) and Blue (-) wires to the battery terminals.
Overall circuit diagram:
For a full size diagram goto: http://mattsnook.com/utv/winch/WinchWiringDiagram1.jpg
Wireless Remote Control Kit diagram:
For a full size diagram goto: http://mattsnook.com/utv/winch/WinchWiringDiagram2.jpg
Install Contactor, Remote Receiver and Manual Switch:
Now run the cables to the contactor mounting area on the firewall. Run the longer Yellow and Blue cables to the battery area and the shorter Red and Black cables to the winch mounting area.
Attach the contactor to the firewall. Go ahead and attach the 4 fat power cables to the contactor on the correct terminals, don't forget to slide on the protective rubber boots first. We'll attach the winch and battery ends last.
I installed the Receiver box for Wireless Remote system in the firewall enclosure behind the dash using zip ties.
For a switched 12v supply I used the wire on the back of the accessory outlet (aka cigarette lighter) wire that is conveniently found in the firewall enclosure as well; just connect the Receiver's red wire that has the inline fuse on it.
I made sure the fuse itself was accessible by poking it through the provided hole in the firewall as in the picture below. Be careful to adjust the rubber ring on the access hole so none of the wires rub against the metal.
Now is the time to also find a place to mount the wired in/out switch (aka "handlebar" switch) that comes with the winch, which also needs to tie into the same 12v source as the wireless Receiver so do them both at once.
I decided to mount it on the tiny shelf on the top of the dash to the left of the steering wheel.
Attach the 3 small wires (spade connections) onto the side of the contactor per the instruction manual (and my Overall diagram provided above).
Assembly winch to winch plate and install it:
The next step is to assemble the winch itself to the winch mounting plate on the bench. This is not complicated just follow directions for your mounting plate and fully torque the mounting bolts because you will not have access to them after the whole winch assembly is attached to the Teryx.
Ok but here is a very important tricky part. When you attach the winch / winch mount assembly to the Teryx (at least with the MotoAlliance MA11933 mount plate), there will be 4 carriage bolts installed from the top side, with the heads being inside the plate and the bolts hanging down loosely. On my 2012 it is helpful to unbolt the 4 bolts holding the radiator and hoist it up with a strap to give more room to insert the winch assembly.
You will then have to install the assembly and get all 4 of these loose bolts to go through the holes in the Teryx mounting area. This is a little tricky and you can use tape over the heads to hold them in place, however here's some...
IMPORTANT ADVICE !!!
IF you are going to also be installing the MotoAlliance snowplow kit at any time later, doing this now will make your life much easier at that point. The reason is you will have to attach their MA11733 plow mount plate by taking the nuts off of the front 2 carriage bolts and mounting the plow mount from beneath.
The problem is the carriage bolts are too short AND are not captive and will just move up as you try to attach to them, AND this plate blocks you from holding the bolt threads from the bottom side.
I have shown this fully on my Snowplow installation thread "MotoAlliance 72" Snow Plow Assembly and Install
" (or my personal website HERE: http://mattsnook.com/utv/snowplow/index.htm
), but the bottom line is that for these 2 front carriage bolts, you have to provide longer (30mm) bolts AND a way to hold the topside heads captive. My solution below is to slide a block of wood that is jammed against the top of the bolt heads so firmly they will not be dislodged later.
Now go ahead and mount the winch assembly onto the Teryx winch mounting area with the 4 carriage bolts (modified as described above).
Do not tighted the 4 bolts yet just snug them so it can still move around a little bit.
Attach the red and black cables to the winch (low torque per instructions).
Install the metal bumper assembly onto the Teryx but do not tighten the 4 bolts fully, also just snug them so the bumper can move.
Insert the fairlead bracket assembly between the winch assembly and the bumper using 2 bolts provided.
Now TIGHTEN ALL BOLTS! Personally I tighten these in a specific order:
First tighten the 2 fairlead bolts fully which needs to pull the winch assembly forward until flush, then tighten the 4 bumper bolts, then finally the 4 winch assembly bottom bolts.
Install the plastic trim over the bumper and the front is done:
Route and connect wires to battery:
Now finalize the routing of the yellow and blue wires to the battery, and add several tie wraps where they go through the tunnel near the driveshaft from front to the engine area. Be sure to place the cables where they will not rub on the driveshaft or the plastic shroud.
Also be careful where they go around sharp metal corners especially near the battery area. To be extra safe I used thick plastic "spiral cable wrap" from a computer store to protect it when it is going across sharp metal edges.
Finally, attach the battery cables and you are DONE DONE!