Kolpin Outdoors 25-0600 User manual

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© 2019 Kolpin Outdoors Inc. REV 00
Application: Verify accessory fitment at Kolpin.com.
Before You Begin: Read these instructions and check to e sure all parts and tools are accounted for. Please retain
these installation instructions for future reference and parts ordering information.
Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877- 56-5746.
ATV / UTV Auto–Winch Stop Kit
Product Instructions | Part No: 5-0600 / 5-0650
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4
1
3
5
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This Kit includes:
Note: Depending
on vehicle
application, extra
wire and/or
hardware may be
necessary.
Item Qty Part Description Part Number
1 1Control Box, Hawse Fairlead 2413444
2
1Narrow Hawse Fairlead (PN 25-0600) -
1Wide Hawse Fairlead (PN 25-0650) -
31Ru er Bumper Magnet Stop -
42Socket Head Cap Screw, Zinc Plated, M10 - 1.5 x 25mm LG -
52Button Screw, Zinc Plated, #10 x 3/4” LG, T25 Torx Drive -
74Scotch Lock Splice Connector -
81Instruction Guide (not shown) -
62Flange Locknut, Zinc Plated, M10 - 1.5 -
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© 2019 Kolpin Outdoors Inc. REV 00
• 13mm Socket and Ratchet
• 8mm Allen Wrench
Tools Required:
• Safety Glasses
• T-25 Torx Driver
Assembly Time: Approximately 60 minutes
Important: Your Kolpin Auto-Winch Stop Kit is universally designed for your vehicle. Please read the installation
instructions thoroughly efore eginning. Installation is easier if the vehicle is clean and free of de ris. For your safety,
and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown. Additional time
may e required to accommodate other installed accessories.
Function of the Auto-Winch Stop Feature: The Auto-Winch Stop fairlead is an innovative solution making your
winch easier to use, especially when plowing. The hardest work your winch does is when it isn’t doing much work at all;
when your winch pulls the rope tight to get the last it of lift out of the plow or to tighten up the hook to prevent it from
rattling against the umper. As the winch pulls the hook against the fairlead it stresses the winch, rope, fairlead, and
vehicle frame. To help prevent damage to these components, Kolpin created a solution that stops the winch efore the
hook is pulled too far into the fairlead.
This auto-winch stop is only for use with synthetic rope, as a steel ca le would quickly wear and damage the aluminum
fairlead. If your vehicle is equipped with steel ca le, you will need to order a synthetic rope. For 4500 l . winch models,
order rope kit PN 85064; for 3500/2500 l . winch models, order rope kit PN 85065. When the ru er ump stop is
rought close to the fairlead, sensors inside the fairlead tell the control ox to turn the winch off. The winch will continue
to let rope out, ut the rope will not pull in any further.
INSTALLATION INSTRUCTIONS:
NOTE: See the Electrical Connections
Reference Guide section of the instruction manual
for detailed photos of each part and their
respective connections.
1. To install this kit, you will need to replace the roller
fairlead with the aluminum Hawse fairlead (item
#2) included with this kit, and install the control ox
(item #1). Both of these operations are fairly
simple, ut pay attention to the details descri ed in
the steps to ensure proper operation. If you are
installing a wireless remote at this time, refer to the
wiring diagram in this kit and use the instructions in
the wireless remote kit to aid in your installation.
2. Shift vehicle transmission into “PARK” or set the
parking rake. Turn ignition key to “OFF” position and
remove from vehicle ignition.
3. Gain access to the attery. Disconnect lack
(negative) and red (positive) ca les from attery as
shown. Retain olts for use during reinstallation. (See
illustration 1-1).
Ill. 1-1
• Pliers
• Wire Cutters
• 7/16” (11.00mm) Drill Bit and
Electric Drill - depending on
vehicle install
WARNING
ALWAYS disconnect lack negative (-) ca le
from attery FIRST. Failure to do so will result
in high current electrical arc, and may result in
attery explosion if tool touches grounded
frame. Death or serious injury may occur.
!
!
Black
ca le
Red
ca le

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© 2019 Kolpin Outdoors Inc. REV 00
INSTALLATION INSTRUCTIONS (continued):
4. Detach lower front fascia as shown if required to
access the fairlead. (See illustration 1-2).
Note, your
vehicle may differ somewhat from illustrations
shown.
5. Remove the two nuts and olts holding the roller
fairlead onto fairlead mounting racket as shown.
(See illustration 1-3).
6. Remove the cotter pin and clevis pin from the hook as
shown to allow the rope to e pulled through the
fairlead. If you have a wire rope, replace it with a
synthetic rope at this time. (See illustration 1-4). Note,
if your fairlead mounting bracket has two smaller
bolt holes than 10mm, you will need to enlarge the
holes to allow the provided M10 screws (item #4)
to fit. Use a 7/16” (11.0mm) drill bit to enlarge the
mounting holes.
7. Thread the rope through the aluminum fairlead (item
#2) so that the side with recessed holes for the
fasteners faces away from the vehicle. Using new
screw (item #4) and nut (item #6) included with this kit,
install the fairlead onto the machine with the wire
pointing toward the passenger side of the vehicle as
shown. (See illustration 1-5).
8. Tighten fasteners to specification.
Ill. 1-2
Front
plastic
fascia
Ill. 1-3
Bolt
Nut
Ill. 1-4
Cotter
pin
Clevis
pin
10MM FASTENER TORQUE:
34 ft. l s. (46 Nm)
Ill. 1-5
4
2
6
Recessed
holes
Wires in
this
direction

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© 2019 Kolpin Outdoors Inc. REV 00
INSTALLATION INSTRUCTIONS (continued):
9. Thread the rope through the ru er ump stop with
the "KOLPIN" la el facing outward, away from the
vehicle as shown. The ru er ump stop (item #3) is
supposed to e tight on the rope, so use a plastic
ca le tie or string (not included), tied around the end
of the rope to pull the rope through the ump stop. It is
helpful to apply a small amount of ru ing alcohol or
other non-corrosive lu ricant to the ru er ump stop
to ease the rope through the hole. Once the rope is
through the hole, attach the hook to the rope with
cotter pin and clevis as mentioned in Step 6. (See
illustrations 1-6 and 1-7). Note, the rope may need to
be first removed from winch spool, then feed rope
thru bumper/fairlead and back into winch spool.
10. Connect the control ox (item #1) to the Hawse
fairlead (item #2). The long wire from the control ox
should e connected to the wires from the fairlead as
shown. (See illustration 1-8).
11. Route the control ox (item #1) and wires along the
main harness to position it close to the contactor.
Disconnect contactor from the main harness, then
reconnect the control ox (item #1) in etween them.
Refer to lock diagram as shown. (See illustration
1-9). Note, scotch lock splice connectors (item #7)
are provided as optional methods of universally
connecting to non-Kolpin winch harnesses.
12. Secure the control ox (item #1) to the frame or wire
harness using ca le ties (not included) or included
screws (item #5). Make sure to secure in a location to
avoid hot or moving parts.
Ill. 1-6
Rope 3
Cotter
pin
Clevis
pin
Ill. 1-7
Ill. 1-8
Ill. 1-9

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© 2019 Kolpin Outdoors Inc. REV 00
INSTALLATION INSTRUCTIONS
(continued):
13. Connect the control ox to the appropriate
power on your vehicle. For RZR and RANGER,
use ring terminal connections to attach to the
keyed power (orange) terminal and ground
( lack) terminal. For ATV, use 1/4" spade
terminal to attach to the orange/white wire on
the main harness underneath the front rack y
the steering post. Attach the lack wire to the
attery or us ar ground connection. Check
and tighten all wire connections and secure any
loose wires using ca le ties.
Note, DO NOT
connect orange wire to battery positive or red wire on terminal block as it will cause the battery to drain.
Connect orange wire ONLY to orange keyed power wire or post.
14. Note, if you are installing the wireless remote control kit (PN 25-0500), connect it etween the vehicle wire harness
and fairlead control ox as shown. (See illustration 1-10).
15. Connect the other end of the fairlead control ox (item #1) to the contactor.
16. Connect the fairlead (item #2) to the fairlead control ox (item #1).
17. Confirm that all wiring is correct and confirm that there are no exposed wires or terminals.
18. All loose wires need to e wrapped tight, and secured away from moving parts and heat sources.
19. Re-install lower front fascia removed in step 4 using hardware previously removed.
20. Re-install red and lack ca les to attery terminals using OEM screws as shown.
21. With vehicle key in the ON position, check winch for proper operation.
Ill. 1-10
For additional assistance, please contact Kolpin customer service department at
[phone] or [phone] or email [email protected]
One Year Limited Warranty
For the period of one (1) year from the purchase date, Kolpin will replace for the original purchaser, free of charge, any part or parts
found upon examination y Kolpin to e defective in material, workmanship, or oth.
All transportation costs incurred su mitting product to Kolpin for warranty consideration must e orne y the purchaser. If Kolpin
determines that the product must e returned to the factory for credit, please call 1-877-956-5746 for a Return Merchandise
Authorization (RMA) num er and shipping instructions.
This warranty does not apply to parts that have een damaged y accident, alteration, a use, improper maintenance, normal wear, or
other causes eyond the manufacturer’s control. In order to protect you and your ATV, certain parts of the accessory system and/or
hardware are designed to fail when the equipment is over-stressed. Parts that are lost due to loosening and improper maintenance
are not covered under warranty. This warranty does not cover removal or reinstallation la or fees of the plow system and related
components.
Peripheral products such as engines, electric motors, and actuators may carry an original manufacturer’s warranty. Most hardware is
general in nature and is easily o tained locally. Be sure to replace with minimum metric class 8.8 specification.

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© 2019 Kolpin Outdoors Inc. REV 00
ELECTRICAL CONNECTION REFERENCE GUIDE:
Winch with Auto-Stop Fairlead
To control switches
(wireless remote, dash
mount, corded remote,
handle ar)
Connect harnesses together
To vehicle
attery power
Connect harnesses together
Item #1
Item #2
To vehicle ground
terminal To vehicle 12V
keyed accessory
power