Polaris 4500 PRO HD Manual de usuario
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 Harness Adapter 2413447
2 2 Dash Switch 4015688
3 2 Routing Clip -
4 1 Wireless Remote Holder -
5 1 Wireless Remote Receiver -
6 1 Wireless Remote -
7 4 Locking Nut - M12 X 1.75 7547441
8 1 Fairlead Mounting Bracket 5258106
Instr 9929140 Rev 01 2018-08 Page 1 of 17
P/N 2883861
POLARIS®® 4500 PRO HD WINCH KIT
Instr 9929140 Rev 01 2018-08 Page 2 of 17
REF QTY PART DESCRIPTION PART NUMBER
9 4 Screw - M12 X 1.75 X 25 7519072
10 1 Rubber Stop Magnet -
11 1 Winch Hook 2411836
12 2 Screw - SH, M10 x 1.5 X 25 7517358
13 1 Fairlead -
14 6 Locking Nut - M10 x 1.5 7547423
15 4 Screw - CAR, M10 X 1.5 X 25 7519372
16 4 Screw - HXFL, M8 X 1.25 X 20 7519133
17 1 Winch Mounting Bracket 5257962
18 2 Screw 7519342
19 1 Control Box -
20 1 Contactor (Included on winch assembly) 4015600
21 1 Battery Cable, Positive 4018231
22 1 Battery Cable, Negative 4018231
23 1 Winch control Harness 2414804
24 6 Screw - TRX, #10 X 3/4 7512026
25 2 Nut, Battery Cable 7547270
26 1 4500 Winch Assembly 2637314
27 1 Winch Rope 2879187
1 Instructions 9929140
TOOLS REQUIRED
• Safety Glasses
• Drill
• Drill Bit: 1/4” (6mm)
• Pliers, Push Pin Rivet
• Pliers, Side Cutting
• Socket Set, Hex Bit, Metric
• Socket Set, Metric
• Socket Set, Torx®Bit
• Torque Wrench
• Wrench Set, Metric
IMPORTANT
Your Polaris®4500 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 48 minutes
NOTE
Additional time may be required for optional steps, or
to accommodate other installed accessories.
Instr 9929140 Rev 01 2018-08 Page 3 of 17
INSTALLATION INSTRUCTIONS
CAUTION
BEFORE STARTING INSTALLATION, always
ensure vehicle is properly secured on a flat stable
surface to avoid accidental tipping, unwanted
movement and to prevent personal injury and/or
damage to equipment. Shift vehicle transmission into
“PARK”. Turn key to “OFF” position and remove from
vehicle.
1. DISCONNECT BATTERY.
WARNING
ALWAYS disconnect black negative (-) cable from
battery FIRST. Failure to do so will result in a high
current electrical arc, and may result in battery
explosion, if tool touches grounded frame. Death or
serious personal injury may occur.
a. Lift the driver side seat latch Alocated behind
seat bottom and remove the driver seat B. Set
seat aside for later reinstallation.
b. Remove battery access panel Cto access the
battery terminals.
c. Disconnect black negative (-) cable from
battery FIRST.
d. Next, disconnect red positive (+) cable from
battery.
2. REMOVE HOOD.
a. Rotate the two hood latches to release the
hood. Pull the hood forward and up to remove
from vehicle.
3. REMOVE WINCH COVER.
a. Remove lower front winch cover Aby
removing four push rivets B.
Instr 9929140 Rev 01 2018-08 Page 4 of 17
4. INSTALL WINCH ASSEMBLY.
a. Slide winch mounting bracket kinto position
from the passenger side as shown. Orient and
align winch mounting bracket to front
suspension bracket and steering bracket as
shown. Secure into position with provided
carriage bolts hand locking nuts g. Torque
fasteners to below specification.
TORQUE
30 ft. lbs. (40.7 Nm)
b. Slide and position winch assembly onto the
winch mounting bracket as shown. Ensure
mounting holes on winch assembly and
mounting brackets are aligned. Use provided
fasteners jto secure winch assembly onto
winch mounting bracket. Torque fasteners to
below specification.
TORQUE
16 ft. lbs. (21.7 Nm)
5. INSTALL AUTOSTOP FAIRLEAD ASSEMBLY.
a. Install Autostop fairlead fto fairlead mounting
bracket iusing the provided screws dand
locking nuts g.
TORQUE
16 ft. lbs. (21.7 Nm)
b. Install fairlead mount bracket iwith autostop
fairlead to suspension bracket with four screws
oand nuts uas shown.
TORQUE
24 ft. lbs. (32.5 Nm)
Instr 9929140 Rev 01 2018-08 Page 5 of 17
6. INSTALL RUBBER STOP MAGNET AND WINCH
HOOK.
a. Shift winch into “neutral” and pull rope/cable 2&
6-12" (15-30 cm) out through fairlead. Thread
rope through rubber stop magnet a, making
sure that the tapered edge with the embossed
"Polaris" logo is facing forward as shown.
Install hook sto the rope by inserting clevis
pin through hook and rope and securing with a
cotter pin.
HINT: Attach a plastic cable tie to the end of
the rope and feed the cable tie through the
rubber stop. Use a little wax or other mild
lubricant on the rubber stop and pull the rope
through the rubber stop using the plastic cable
tie.
7. INSTALL WIRELESS RECEIVER.
a. Use supplied cable ties to secure the wireless
remote receiver to the chassis in the location
shown below with power/control wires facing
towards the center of the vehicle.
Wire routing and connections will be completed
in step 9 once all components have been
mounted.
8. INSTALL DASH SWITCH.
a. Remove dash switch panel Aby gently pulling
out along the edges. Once dash panel is out,
remove switch plug B.
b. Install dash switch qinto the mounting hole by
pressing the switch firmly into position until it is
fully seated as shown.
Instr 9929140 Rev 01 2018-08 Page 6 of 17
9. CONNECT ALL ELECTRICAL COMPONENTS.
NOTE
Refer to the Electrical Connection Reference Guide
section at the back of the instruction manual for
images and detailed harness connection illustrations
of the proper electrical connections to aid in the
remaining electrical connections.
IMPORTANT
When making connections, ensure all wires are
routed and secured with cable ties away from all
heat sources, moving components and sharp edges.
Failure to do so may cause damage to electrical
wires and/or underlying components which may
cause the winch to malfunction.
a. Locate the dash switch connector (23B) and
connect it to the dash switch was shown.
Once connected, reinstall dash switch panel by
aligning all mounting tabs with corresponding
slots and firmly press back into the original
position.
b. Next connect the winch contactor connector
(19B) and connect it to the control box
connector (23D).
c. Connect the Autostop fairlead connector (13A)
to the control box connector (19A).
d. Connect the wireless receiver harness
connector (5A) to the control box connector
(19C).
e. Locate the wireless receiver connector (5B)
and connect it to the dash switch connector
(23E).
Instr 9929140 Rev 01 2018-08 Page 7 of 17
f. Next connect the pulse bar dash switch
connector (23A) to the pulse bar connection A
as shown. For MY19 and newer vehicles skip
step 9g and proceed to step 9h.
NOTE
For MY18 and older vehicles that are equipped with
a busbar style electrical power distribution strip you
will also need to connect the busbar adapter. Refer
to the image and procedures outlined in step 9g for
busbar connections.
g. For vehicles with a busbar you will need to first
remove the cable connection nut Efrom the
keyed power terminal Band install the orange
wired terminal (1B) on the busbar harness
adapter onto the keyed power terminal Bof
the busbar. Reinstall the cable connection nut
Eand torque to specification provided.
TORQUE
36 in. lbs. (4.1 Nm)
Remove the cable connection nut Efrom the
negative terminal on the busbar and install the
black wired terminal (1C) on the busbar
harness adapter onto the negative terminal of
the busbar and loosely reinstall the cable
connection nut E.
Next, remove the cable connection nut from the
positive terminal on the busbar and install the
red wired terminal (1D) on the busbar harness
adapter onto the positive terminal of the busbar
and loosely reinstall the cable connection nut
E.
h. Route the fuse block (23G) behind the pulsebar
and fasten to firewall by using a drill and 1/ 4”
drill bit to drill out the dimpled hole location as
shown in image 9f.
Instr 9929140 Rev 01 2018-08 Page 8 of 17
i. Connect the red positive (+) and black negative
(–) power cables to the corresponding positive
(+) and negative (–) terminals on the pulse bar
or busbar.
MY 19 and newer vehicle use the provided
cable connection nuts 2% to secure the power
cables in place as shown below. Torque to
specification provided.
TORQUE
24 in. lbs. (2.8 Nm)
MY18 and older you will need to route and
secure the red positive (+) and black negative
(–) power cables with the existing cable
connection nuts to the corresponding positive
(+) and negative (–) busbar terminals as shown
in the image below. Torque all nuts to
specification provided.
TORQUE
36 in. lbs. (4.1 Nm)
j. Ensure all wires are secured in place away
from all moving parts, sharp edges and heat
sources with provided cable ties.
10.CONNECT BATTERY.
WARNING
When BOTH battery cables are disconnected
ALWAYS reconnect AND tighten red positive (+)
cable to battery FIRST. Failure to do so will result in
a high current electrical arc, and may result in battery
explosion, if tool touches grounded frame. Death or
serious personal injury may occur.
a. Reinstall red positive (+) cable to positive (+)
battery terminal.
b. Reinstall black negative (–) cable to negative
(–) battery terminal.
c. Reinstall battery access panel C.
Instr 9929140 Rev 01 2018-08 Page 9 of 17
11. REINSTALL SEAT.
a. Lift the driver side seat latch Alocated behind
seat bottom and firmly press down on seat
bottom to reinstall the driver seat B. Once
installed, pull forward on the seat back to
ensure the seat is fully latched and secured
into position.
12.REINSTALL WINCH COVER.
a. Reinstall lower front winch cover Awith the
previously removed four push pin rivets B.
13.REINSTALL HOOD.
a. Place hood into position and rotate the two
hood latches to secure into position.
14.OPTIONAL STEP - INSTALL WIRELESS
REMOTE.
a. Wireless remote holder can be installed in
desired location on vehicle. Use screws
supplied in the wireless remote kit for holder
installation. Location shown is for
REFERENCE ONLY.
15.VERIFY WORK.
a. Confirm all electrical wires/connections have
been routed and connected per instructions.
b. Confirm that there are no exposed wires or
terminals.
c. Ensure all loose wires are secured away from
moving parts, sharp edges and heat sources.
Instr 9929140 Rev 01 2018-08 Page 10 of 17
16.VERIFY WINCH FUNCTION.
a. With the vehicle key in the “ON” position, check
winch for proper operation.
i. Shift winch into each of the three gear
settings, HIGH/LOW/NEUTRAL, and verify
proper function.
ii. 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.
iii. If the Autostop is not functioning properly,
see troubleshooting information at the end
of the instructions.
Este manual sirve para los siguientes modelos
1
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