KFI Assault ASP-35 Manual

Model #ASP-35
Owner’s Manual and Operating Instructions
3500 lb.
ATV/UTV WINCH
Revision Date 2019-04-01


5ASP-35
Table of Contents
Introduction��������������������������������������������������������������������������������� 1
Accessories �������������������������������������������������������������������������������������������������������1
This Booklet �����������������������������������������������������������������������������������������������������1
Introduction��������������������������������������������������������������������������������� 1
ManualConventions������������������������������������������������������������������� 2
SafetyRules���������������������������������������������������������������������������������� 3
ControlsandFeatures����������������������������������������������������������������� 5
Winch ���������������������������������������������������������������������������������������������������������������5
Installation������������������������������������������������������������������������������������ 6
Step 1-ATV Install Preparation ������������������������������������������������������������������������6
Step 2-Winch Assembly Preparation ����������������������������������������������������������������7
Step 3-Install Winch Assembly �����������������������������������������������������������������������8
Step 4-Handlebar Remote Install ����������������������������������������������������������������������9
Step 5-Reinstall ������������������������������������������������������������������������������������������������9
Operation������������������������������������������������������������������������������������ 10
General Tips for Safe Operation ���������������������������������������������������������������������10
Self Recovery �������������������������������������������������������������������������������������������������10
Winching Techniques ������������������������������������������������������������������������������������11
Maintenance������������������������������������������������������������������������������� 12
Motor ��������������������������������������������������������������������������������������������������������������12
Lubrication �����������������������������������������������������������������������������������������������������12
Cable Assembly Replacement ������������������������������������������������������������������������12
ASP-35Specifications��������������������������������������������������������������� 13
Performance Specifications ����������������������������������������������������������������������������13
Model Winch Diagram �����������������������������������������������������������������������������������14
Winch Parts List ���������������������������������������������������������������������������������������������15
Troubleshooting������������������������������������������������������������������������� 16
PlowingAlert������������������������������������������������������������������������������ 16
Warranty������������������������������������������������������������������������������������ 17
Warranty Qualifications ���������������������������������������������������������������������������������17
Repair/Replacement Warranty �����������������������������������������������������������������������17
Do not return the unit to the place of purchase ����������������������������������������������17
Warranty Exclusions ��������������������������������������������������������������������������������������17
Normal Wear �����������������������������������������������������������������������������������������������17
Installation, Use and Maintenance �����������������������������������������������������������������17
Other Exclusions ��������������������������������������������������������������������������������������������17
Limits of Implied Warranty and Consequential Damage �������������������������������17
Contact Information ����������������������������������������������������������������������������������������18
Address �����������������������������������������������������������������������������������������������������������18
Corporate: �������������������������������������������������������������������������������������������������������18
Customer Service ��������������������������������������������������������������������������������������������18
Technical Service �������������������������������������������������������������������������������������������18
Agreement ������������������������������������������������������������������������������������������������������18
SyntheticCable������������������������������������������������������������������������� 19


1
ASP-35
Introduction
Introduction
Congratulations on your purchase of a KFI winch.
KFI researches and develops winches to strict
specications. With proper use and maintenance,
this winch will bring years of satisfying service.
Accessories
Kappers Fabricating Inc. manufactures,
purchases and sells accessories designed to
help you get the most from your purchase. To nd
out more about our products visit our web site at
www.kproducts.com
Record the model as well as date and place of purchase for future reference. Have this information
available when ordering parts and when making technical or warranty inquiries.
This Booklet
Every effort has been made to ensure the
accuracy and completeness of the information in
this manual. We reserve the right to change, alter
and/or improve the product and this document at
any time without prior notice.
Kappers Fabricating Inc� Support
1-877-346-2050
Model Number
ASP-35
Date of Purchase
Purchase Location
Serial Number

2ASP-35
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
Manual Conventions
This manual uses the following symbols to
help differentiate between different kinds of
information. The safety symbol is used with a key
word to alert you to potential hazards in operating
and owning a winch.
Follow all safety messages to avoid or reduce the
risk of serious injury or death.
Manual Conventions
DANGER
NOTE
If you have questions regarding your winch,
we can help. Please call our help line at
1-877-346-2050.
WARNING
CAUTION
CAUTION

3
ASP-35
Manual Conventions
Safety Rules
Do not use this winch for lifting or moving
people or animals.
DANGER
Read this manual thoroughly before operating
your winch. Failure to follow instructions could
result in serious injury or death.
WARNING
Do not move the vehicle to pull a load (towing)
on the winch cable. This could result in cable
breakage.
WARNING
Pull only on areas of the vehicle as specied
by the vehicle manufacturer.
WARNING
Do not exceed the rated capacity.
WARNING
Keep yourself and others a safe distance from
the side of the cable when under tension.
WARNING
Never step over a cable or near a cable under
load.
WARNING
The cable may break before the motor stalls.
For heavy loads at or near rated capacity, use
a pulley block/snatch block to reduce the load
on the wire rope.
WARNING
Do not use the winch to secure or hold a
vehicle for a long period of time. Do not use
the winch to secure a vehicle for transport.
WARNING
Disconnect the remote control and battery
leads when not in use for extended periods.
WARNING
Avoid “shock loads” by using the control switch
intermittently to take up the slack in the wire
rope. “Shock loads” can far exceed the rate
capacity for the cable and drum.
Do not accelerate your vehicle while winching.
Loss of traction can cause a shock load on the
cable. Do not use cable as a pull strap.
WARNING

4ASP-35
Do not use as a hoist. Do not use for overhead
lifting.
Safety Rules
WARNING
Batteries contain acid and produce explosive
gases.
Keep sparks, ames and cigarettes away from
batteries at all times. Wear safety glasses and
protect the eyes at all times. Do not lean over
the batteries during operation.
WARNING
When re-spooling the cable, ensure that the
cable spools in the under-wind position with
the cable entering the drum from the bottom,
not the top.
To re-spool correctly, and while wearing
gloves, keep a slight load on the cable while
pushing the remote button to draw in the
cable. Walk toward the winch not allowing the
cable to slide through your hands. Do not let
your hands get within 12” of the winch while
re-spooling. Turn off the winch and repeat
the procedure until a few feet of cable is left.
Disconnect the remote control and nish
spooling by rotating the drum by hand with
the clutch disengaged. Keep hands clear of
the fairlead and drum while the winch is under
power.
WARNING
Duration of winching pulls should be kept as
short as possible.
If the motor becomes uncomfortably hot to
the touch, stop winching immediately and let
it cool down for a few minutes. Do not pull for
more than one minute at or near the rated
load.
CAUTION
Apply blocks to the wheels of the vehicle when
on an incline.
CAUTION
Do not wrap the cable around any object and
hook it back onto itself.
CAUTION
Use gloves to protect hands when handling the
cable. Never let the cable slide through your
hands.
CAUTION
If the motor stalls, do not maintain power to
the winch.
Electric winches are designed and made for
intermittent use and should not be used in
constant duty applications.
CAUTION
Never release the release clutch when there is
a load on the winch.
CAUTION
Use hook strap when handling the hook for
spooling or unspooling the cable.
CAUTION

5
ASP-35
1
11
3
8
10
12
9
13
6
7
4
2
Controls and Features
Read this owner’s manual before operating your winch. Familiarize yourself with the location and
function of the controls and features. Save this manual for future reference.
Motor (1): 1.15 HP 12V DC motor provides power
to the planetary gear mechanism.
Winch Drum (2): The winch drum is the cylinder
on which the cable is stored. It can feed or wind
the rope depending on the remote winch switch.
Synthetic Cable (3): 3/16” x 50’ Synthetic cable
designed specically for load capacity of 3,500lbs.
(48 useable feet with ve wraps on the drum). The
synthetic rope feeds onto the drum in the “under
wind” position through the roller fairlead (4) and
is looped at the end to accept the clevis hook pin
(11).
Roller Fairlead (4): When using the winch at an
angle the roller fairlead acts to guide the synthetic
rope onto the drum and minimizes damage to the
synthetic rope from abrasion on the winch mount
or bumper.
Free spooling Clutch (5): The clutch allows the
operator to manually disengage (“RELEASE”) the
spooling drum from the gear train. Engaging the
clutch (“ENGAGE”) locks the winch into the gear
system.
Braking System (6): Braking action is
automatically applied to the winch drum when the
winch motor is stopped and there is a load on the
synthetic rope.
Planetary Gear System (7): The reduction gears
convert the winch motor power into extreme
pulling forces. This system allows high torque
while maintaining compact size and light weight.
ATV Plug & Play Rocker Switch (8): Handlebar
mounted switch for easy access. Plugs directly
into factory harness
Model Specic Winch Mount (9): Winch mount
designed specically for ATV.
Contactor (10): Power from the vehicle battery
ows through the weather sealed solenoid switch
before being directed to the winch motor.
Clevis Hook (11): Provides a means for
connecting the looped ends of cables to an
anchor.
Cable Hook Stopper (12): Protects the Rollers,
motor and gears.
Wires (13): Model Specic Pre-installed Wires
Winch
5

6ASP-35
This KFI 3,500 lb Plug & Play winch assembly is
designed to be a direct t up to the specic ATV
Models from our online application chart.
1. On the 850 and 1000 Models remove the
front rack to gain access to the battery.
Disconnect the battery.
2. On the ETX, 450 and 570, open the front
rack and remove the center cover [A] by
removing the (4) Torx fasteners. You will
also need to lightly pull the rubber seal out
of the groove around the center cover to be
removed as shown in Figure 1.
3. Remove any added on bumpers or brush
guards.
4. Remove the lower cowling [B] on the
Sportsman models and the bumper [C] and
front assembly clip [D] on the Scramblers as
shown in Figure 2-5.
5. Remove and discard the Winch pocket
cover [E] shown in Figure 2-5.
6. Remove the winch assembly from the box
and cut the zip tie that is holding the power
wires for packaging.
Step 1-ATV Install Preparation
Installation
Before you start to install this winch,
disconnect the vehicle ground and positive
leads from the battery. (ETX, 450 and 570
battery is located lower front frame and the
850 and 1000 is located under the front rack
WARNING
Installation
“Figure 2”
ETX, 450 and 570
“Figure 3”
Scrambler
“Figure 4”
850 Sportsman “Figure 5”
850 & 1000 Sportsman
“Figure 1” A
B
B
C
D
B
E
E
E
E

7
ASP-35
Installation
This winch assembly comes pre-assembled and
ready to go for the 850 and 1000 Polaris ATV’s. If
you have the 850 or 1000 please skip this step. If
you have the ETX, 450 or 570 ATV please continue
with this step.
1. Remove the (2) self tapping crews [F] holding
the contactor [G] down in the back of the as-
sembly as shown in Figure 6.
2. Move the contactor [G] to the new location
on the side of the mount, as shown in Figure
7. Make sure the contactor plug [H] is in the
orientation shown in Figure 7. To mount the
contactor, re-use the self-tapping screws [F].
3. While mounting the contactor to the new loca-
tion you will want to route the wires around the
winch as shown in Figure 8 & 9. You should
not have to loosen any of the pre-connected
wires.
Step 2-Winch Assembly Preparation
F
F
“Figure 7”
H
G
“Figure 6”
F
F
G
“Figure 8” “Figure 9”

8ASP-35
Installation
Step 3-Install Winch Assembly
1. Place winch into frame location while routing
winch positive and negative wires to the loca-
tion under the front rack and install (4) bolts,
lock washers and washers loosely as shown in
Figure 10 & 11.
2. On the 850 and 1000 connect the positive and
negative wires directly to the battery terminals.
3. On the ETX, 450 and 570 connect the positive
and negative wires to the Buss Bar as shown
in Figure 12.
4. Tighten down the (4) bolts to secure the winch
assembly to the frame.
5. Locate the White plug OEM pre-wired 2-pin
connector, located near the winch assembly
on the driver’s side (approximate location is
shown in Figure 10 [J]). This wire will have a
green and black wire going into the white plug.
Most 2015 and newer ATV’s will have this
pre-wired plug installed from the factory. Most
2014 and older models will require the pur-
chase of this additional wire harness. Polaris
Part #4015094. Please refer to application
chart for details.
6. Cut the zip tie holding the wire to the frame
and remove the protective cap.
7. Route the wire over to the contactor location
on the winch assembly and connect it to the
other 2-pin connector [K] that is coming out of
the contactor shown in Figure 11.
8. Secure this wire if needed with zip ties.
Never route electrical cables across any sharp
edges, through or near moving parts, or near
parts that become hot. Routing of the battery
wires will be on the passenger side of the
vehicle, just behind the radiator. Stay clear of
cooling fan and use zip ties to secure wire in
place.
CAUTION
Battery cables should not be drawn taut. Leave
some slack for cable movement.
CAUTION
FAILURE TO FOLLOW SPECIFIC WIRING
INSTRUCTIONS MAY RESULT IN DAMAGE TO
YOUR WIRING SYSTEM OR EQUIPMENT.
WARNING
+
-
Positive
Negative
“Figure 12” Buss Bar on ETX, 450 & 570
“Figure 10”
850 & 1000 Sportsman shown
EXT, 450 & 570 will be similar
J
“Figure 11”
850 & 1000 Sportsman assembly shown
EXT, 450 & 570 will be similar
K

9
ASP-35
Installation
Step 4-Handlebar Remote Install
1. Cut zip tie retaining handle bar wires [L].
2. Locate factory integrated harness connector
and remove protective cap [M].
3. Mount the switch assembly [N] to handlebar
location as shown.
4. With the switch mounted, attach the switch
plug [O] to the integrated plug [M], and install
a new zip tie at location [L].
L
N
O
M
Step 5-Reinstall
1. Turn your ATV ignition on and test the winch
operation.
2. On the EXT, 450 and 570 re-assemble the
center cover [A] from step 1.2 and close the
front rack.
3. On the 850 and 1000 models re-assemble the
front rack.
4. On all models, re-install the front lower cover,
front clip on the scramblers and any aftermar-
ket bumpers removed from steps 3 and 4.

10 ASP-35
Your winch is equipped with a roller fairlead to help
guide the cable and to reduce binding on short side
pulls�
Do not winch from an acute angle as the cable will
pile up on one side of the drum causing damage to
cable and the winch�
Short pulls from an angle can be used to straighten
the vehicle� Long pulls should be done with the
cable straight out from the winch/vehicle�
When pulling a heavy load, place a cable hook
stopper, blanket or jacket over the cable five or six
feet from the hook�
In the event of a cable snap it will dampen the snap
back� For additional protection open the hood of the
vehicle�
General Tips for Safe Operation
Your ASP-35 winch is rated at 3,500 lbs. capac-
ity in rst layer (max) when spooling the rst rope
layer on the drum. Overloads can damage the
winch, motor and/or cable.
The vehicle engine should be kept running during
operation of the winch to minimize battery drain
and maximize power and speed of the winch. If
the winch is used for a considerable time with the
engine off the battery may be drained and too
weak to restart the engine.
Get to know your winch before you actually need
to use it. We recommend that you set up a few test
runs to familiarize yourself with rigging techniques,
the sounds your winch makes under various loads,
the way the cable spools on the drum, etc.
Inspect the cable and equipment before each use.
A frayed or damaged rope should be replaced
immediately. Use only manufacturer’s identical
replacement rope with the exact specications.
Inspect the winch installation and bolts to ensure
that all bolts are tight before each operation.
Store the remote control inside your vehicle in a
place that it will not be damaged.
Any winch that appears to be damaged in any
way, is found to be worn, or operates abnormally
MUST BE REMOVED FROM SERVICE UNTIL
REPAIRED. It is recommended that the necessary
repairs be made by a manufacturer’s authorized
repair facility.
Pull only on areas of the vehicle as specied by
the vehicle manufacturer.
Only attachments and/or adapters supplied by the
manufacturer are to be used.
Operation
Self Recovery
Locate a suitable anchor such as a strong tree
trunk or boulder. Always use a sling as an anchor
point.

11
ASP-35
Operation
Winching Techniques
1. Take time to assess your situation and plan
your pull.
2. Put on gloves to protect your hands.
3. Disengage the clutch to allow free-spooling
and also save battery power.
4. Attach the hook strap to the clevis hook.
5. Pull out the cable to your desired anchor
point using the hook strap.
6. Secure the clevis hook to the anchor point:
Sling, chain or snatch block. Do not attach
the hook back onto the cable.
7. Engage the clutch.
8. Start your engine to ensure power is being
replenished to the battery.
9. Power in the cable guiding the cable under
tension to draw up the slack in the cable.
Once the cable is under tension, stand
clear. Never step over the cable.
10. Double check your anchors and make sure
all connections are secure.
11. Inspect the cable. Make sure there are at
least 5 wraps of cable around the winch
drum.
12. Place cable hook stopper over the cable
approximately 5 to 6 feet from the hook.
13. Clear the area. Make sure all spectators
stand clear and that no one is directly in
front or behind the vehicle or anchor point.
14. Begin winching. Be sure that the cable
is winding evenly and tightly around the
drum. The vehicle that is being winched can
be slowly driven to add assistance to the
winching process. Avoid shock loads; keep
the cable under tension.
15. The vehicle to be winched should be placed
in neutral and the parking brake released.
Only release the loads to the winch. This
can damage the winch, cable and vehicle.
16. The winch is meant for intermittent use.
Under full load with a single line rig do not
power in for more than a minute without
letting the motor cool down for a few
minutes and then resume the winching
operation.
17. The winching operation is complete once
the vehicle is on stable ground and is able
to drive under its own power.
18. Secure the vehicle. Be sure to set the
brakes and place the vehicle in park.
19. Release the tension on the cable. The winch
is not meant to hold the vehicle for long
periods of time.
20. Disconnect the cable from the anchor.
21. Rewind the cable. Make sure that any cable
already on the drum has spooled tightly
and neatly. If not, draw out the cable and
re-spool from the point where the cable is
tight.
22. Keep your hands clear of the winch drum
and fairlead as the cable is being drawn in.
23. Secure the hook and hook strap.
24. Disconnect the remote control and store in a
clean, dry place.
25. Clean and inspect connections and mount-
ing hardware for next winching operation.
26. Never use the winch as a tie down.
27. Use brake pedal when under full tension.

12 ASP-35
Maintenance
The owner/operator is responsible for all periodic
maintenance.
Improper maintenance will void your warranty.
Never operate a damaged or defective winch.
NOTE
For service or parts assistance, contact our help
line at 1-877-346-2050.
WARNING
WARNING
Complete all scheduled maintenance in a timely
manner. Correct any issue before operating the
winch.
Lubrication
All moving parts within the Electric Winch have
been lubricated using high temperature lithium
grease at the factory. No internal lubrication is
required under normal conditions. If the winch is
subjected to extreme conditions lubrication may be
required using a high temperature lithium grease.
Cable Assembly Replacement
It is recommended that any modications be
performed by a manufacturer’s authorized repair
facility, and that only manufacturer-supplied parts
be used.
1. Rotate the clutch cap to the “Release”
position.
2. Extend Cable Assembly to its full length. Note
how the existing cable is connected to the
inside of the drum.
3. Remove old Cable Assembly and attach new
one.
4. Rotate the clutch cap to the “Engage”
position.
5. Retract Cable Assembly onto drum being
careful not to allow kinking or over heating of
the winch.
Maintenance
Motor
Periodically, when not used very often, or after
wet / damp conditions, be sure to run the motor in
free spool until the motor is warm. This helps dry
out any moisture and condensation trapped inside
the housing.

13
ASP-35
ASP-35 Specications
Performance Specications
Rated Pull 3,500 lbs (1589 kg)
Gear Reduction Ratio 180:1
Motor Permanent Magnet
1.15 HP/0.89kW (DC 12V)
Drum Size 1.75” (D) x 3.19” (L)
44.5 mm (D) x 81.0 mm (L)
Synthetic Cable 3/16” (D) x 50.0’ (L)
4.8 mm (D) x 15.24 m (L)
(48 useable feet with ve
wraps on the winch drum)
Weight 26.0 lbs. (NET)
Height 4.76 inches (121 mm)
Width 4.44 inches (113 mm)
Length 13.62 inches (346 mm)
Bolt Pattern 4-7/8” x 3” (124mm x 76 mm)
Line Speed and Motor Current (First Layer)
Line Pull Max lbs 0 1000 2000 2500 3500
kgs 0 454 907 1134 1589
Line Speed
(12 VDC)
FPM 12.1 10.8 8.2 7.5 4.9
MPM 3.7 3.3 2.5 2.3 1.5
Max Current amps 28 60 90 115 180
Cooling Time minutes 5 5 5 5 5
Line Pull and Cable Capacity
Layers of cable on drum 1 2 3 4 5
Max pulling capacity per
layer
lbs 3500 2907 2486 2171 1927
kgs 1589 1320 1128 986 875
Cable capacity
per layer
ft 7.9 17.7 28.9 41.7 50.0
m 2.4 5.4 8.8 12.7 15.25

14 ASP-35
ASP-35 Specications
Model Winch Diagram

15
ASP-35
ASP-35 Specications
Winch Parts List
No Part# Description Qty
01 MOTOR-AS35 Motor Assembly 1
02 410018-B Bolt M5 x 16 2
03 450001 Coupling, I 1
04 450003A Coupling, II 1
05 410001 Spring 1
06 500001 Self-Seal Packing 2
07 500018 Tie Bar Φ10 2
08 500002A Clutch Cover 1
09 410005 Gear Ring I 1
10 AS350001 Gear Carrier Assembly,
Output 1
11 410009 Gear Carrier Assembly,
Input 1
12 GB2760BB0606-
2RS
Radial Ball Bearing 606
Sealed 1
13 500003 O-Ring Φ19 x 2.4 1
14 410014 Clutch Spring 1
15 GB2760BB6802-
2RS
Radial Ball Bearing
6802 Sealed 1
16 500004 Clutch Cap 1
17 450030-B Cap Screw M6 x 16 1
18 250017-B Washer Φ6, Locking 1
19 250011 Circlip Φ15 1
20 500005 Bolt M4 x 20 1
21 500006 Washer Φ4, Flat 2
22 500007A Gear Housing 1
23 500008 Cam Clutch Gear 1
24 500009 Axis Support Bushing 1
25 410015 Sun Gear, Input 1
26 AS250002 Gear Carrier Assembly 1
27 410007A Gear Ring II 1
28 410004A O-Ring Φ100 x 1.9 1
29 410016 Drum Bushing 2
30 500010A Hexagon Tie Bar 6 x 87mm 1
31 500011 Hexagon Socket Set
Screw M5 x 8 1
32 AS350100 Drum Assembly 1
33 500012 Hexagon Shaft 1
34 450002 Spring, Coupling 1
35 AP-BAT-WIRE1 Battery Wire with Loom
Covering - Red 1
No Part# Description Qty
36 AP-BAT-WIRE2 Battery Wire - Black 1
37 AP-WIN-WIRE Winch Wires - Blue/Yellow 2
38 AP-MR Mini Rocker Switch 1
39 250047-BF MR Mounting Angle 1
40 250054-B Washer #6, Locking 2
41 250053-B Screw #6-32 x 9/32 in. 2
42 250052-B Nut M5 2
43 250045-BF Handlebar Switch
Clamp 2
44 250050-B Washer Φ5, Locking 2
45 250049-B Washer Φ5, Flat 2
46 250051-B Screw M5 x 18 3
47 AM250003
Hexagonal Socket
Button Head Screw
M8 x 25
4
48 250063-B Washer Φ8, Locking 4
49 250070-B Washer Φ8, Flat 8
50 AM250004 Carriage Bolt M10 x 25 2
51 NV-740 Sportsman Winch
Mount - Wrinkle Texture 1
52 SE-RF Roller Fairlead, POM
Rollers 1
53 250036-B Locking Nut M10 2
54 AP-CONT Contactor(11D2) 1
55 SYN19-S50 Synthetic Cable, 3/16
in. x 50 ft 1
56 SE-HOOK Clevis Hook - Black
E-Coat 1
57 250030-B Strap - Black 1
58 250032-B Bolt M8 x 25 4
59 ATV-SCHS Split Cable Hook Stop-
per 1
60 AM250005
Hexagonal Flange
Self-Threading Screw
M5 x 25
2
61 250061 Terminal Protector 6
62 AS-CAPKIT End Cap Assembly 1
63 450026-B Bolt M4 x 25 1
64 500016 Square Nut 4
65 500017 Elastic Cylindrical Pin
Φ3 x 14 4
66 250048-B Screw M5 x 25 1

16 ASP-35
Troubleshooting
Problem Cause Solution
Winch runs one way
Defective or Stuck Contactor Tap Contactor to loosen plungers.
Repair or Replace Contactor.
Defective Switch Assembly Replace Switch Assembly.
Contactor Issue
Double check your winch wiring diagram to make
sure all wires are correct.
Refer to our contactor troubleshooting guide at
www.kproducts.com under “Support”
Call KFI Technical support
Contactor clicks but the
winch does not run
Wired Incorrectly
Double check your winch wiring diagram to make
sure all wires are correct.
Hand remote / Dash rocker wires need to always
be green to green and black to black.
Call KFI Technical support
Motor Issue Call KFI Technical support
Brake Spring installed backwards Call KFI Technical support
Motor runs but the cable
is not moving
Cable is not Attached to the Spool Refer to our cable retie guide at
www.kproducts.com under “Support”
Winch is not engaged Rotate the clutch cap to “engage”
Broken coupler or Stripped shaft Replace Coupler / Shaft
Motor runs slowly or
without normal power
Worn Brushes Get a replacement End-Cap #A-CAPKIT
Call KFI Technical support
Loose or corroded cable connections Clean, Tighten, or Replace
Motor is overheating Winch running time is too long Allow winch to cool down periodically.
WARNING
PLOWING ALERT
READ BEFORE USING YOUR WINCH TO LIFT A PLOW
ATV winches are one of the most widely used methods of lifting a plow. When used properly they are
a perfect match to any plow system but proper precautions and correct usage are required to prevent
costly damage.
When lifting a plow using a winch it is very important to stop the plow before its full lift height is reached.
Failure to do so will cause the winch to pull against itself and can, and most likely will, cause damage to
the winch, your plow frame and your ATV.
Please remember that winch damage such as stripped gears, broken housings and bent and damaged
parts caused by exceeding your plows lift height are not covered by warranty.
Special precautions should be taken when backing up or other instances where you may be distracted
and forget your nger is still on the power-in switch.
A little practice and common sense will ensure a trouble free plow season and prolong the life of your
equipment.
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