Kolpin Outdoors 26-1020 Instruction sheet

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© 2019 Kolpin Outdoors Inc. REV 00
Honda Rancher / Foreman / Rubicon
Quick-Mount 2500lb. / 3500lb. Winch Kit
Product In truction | Part No: 26-1020 / 26-1030
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Application: Honda Ranch r 420 / For man 500 / Rubicon, v rify acc ssory fitm nt at Kolpin.com.
Before You Begin: R ad th s instructions and ch ck to b sur all parts and tools ar account d for. Pl as r tain
th s installation instructions for futur r f r nc and parts ord ring information.
Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877- 56-5746.
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© 2019 Kolpin Outdoors Inc. REV 00
Thi Kit include :
• Wr nch S t, M tric
• Torqu Wr nch
Tool Required:
• Saf ty Glass s
• Sock t S t, M tric
Item Qty Part De cription
Part Number
26-1020 26-1030
1 1Handl bar Switch & Acc ssory Pow r Harn ss -
25Cabl Ti s, Nylon -
312 H x Flang Scr w, Zinc Plat d, M8 x 1.25 - 20mm LG 7518450
41Winch Mounting Brack t 25-1270
51Winch - Kolpin, 2500lb. / 3500lb. 25-9250R 25-9350R
61Hook, Winch Latch RPR0108
71Winch Cabl , (St l - 2500lb.) / (Synth tic - 3500lb.) 85062 85064
81Winch Conn ction Cabl , Y llow 6 GA (342mm) -
91Winch Conn ction Cabl , Blu 6 GA (203mm) -
10 1Pow r Conn ction Cabl , Black 6 GA (2134mm) -
11 1Pow r Conn ction Cabl , R d 6 GA (2184mm) -
12 1Contactor, Sol noid, 12V 85068
13 1Roll r Fairl ad 85069
14 1Rubb r Winch Stopp r (only includ d on 3500lb.) - 85080
15 1Roll r/Contactor Mounting Brack t 25-1270
16 2Sock t H ad Cap Scr w, Zinc Plat d, M6 x 1.0 - 10mm LG 7517337
17 4H x Flang Locknut, Zinc Plat d, M8 x 1.25 7547317
18 2Routing Clip Cabl Ti , Nylon 7081496
19 1Instruction Guid (not shown) -
20 - S rvic Fr Spool Handl Knob (not includ d in kit) 85072
A embly Time: Approximat ly 30 minut s
Note: The 26-1020 / 26-1030 kits come mostly assembled from factory. Some assembly is required.
Important: Your Kolpin Honda ATV Quick-Mount Winch Kit is xclusiv ly d sign d for your v hicl . Pl as r ad th
installation instructions thoroughly b for b ginning. Installation is asi r if th v hicl is cl an and fr of d bris. For
your saf ty, and to nsur a satisfactory installation, p rform all installation st ps corr ctly in th s qu nc shown.
• Pli rs
• Torqu Wr nch

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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON
PREPARATION:
1. Shift v hicl transmission into “NUETRAL” and
s t th PARKING BRAKE. Turn k y to “OFF”
position and r mov from v hicl .
2. R mov th OEM bolts that s cur th front half
of th bottom plastic ngin guard. Th front half
of th plastic guard will fl x downwards, providing
acc ss to install winch kit as shown. If mor
acc ss is d sir d, th ntir plastic guard can b
r mov d from v hicl . R tain bolts for us during
r installation. (S illustration 1-1).
3. R mov th front bump r tubing from th v hicl
as shown by r moving th ight OEM fast n rs
(two on front rack, two s cur plastic c nt r grill
and four attach fram tubing to v hicl main
chassis). R tain bolts for us during
r installation. (S illustrations 1-1, 1-2 and 1-3).
Note, the front bumper shape will vary slightly
depending on vehicle model.
4. R mov th s at and tank cov r ass mbly from
th v hicl as shown. Not , th tank cov r
ass mbly is h ld into position using body pan l
locating tabs pr ss d into rubb r gromm ts.
R f r to th s rvic manual for xtra d tails.
(S illustration 1-4).
Ill. 1-1
Fl x plastic guard
Ill. 1-2
Ill. 1-3
FRONT
Bump r
bolt
Ill. 1-4
Rubb r
gromm ts
Front
bump r
tubing

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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON PREPARATION
(continued):
5. R mov th r ar f nd r cov r to acc ss th batt ry.
Disconn ct black (n gativ ) and r d (positiv ) cabl s
from batt ry as shown. R tain bolts for us during
r installation. (S illustration 1-5).
6. R mov th Honda ATV winch sub-ass mbli s from th
packaging.
RANCHER / FOREMAN / RUBICON WINCH
INSTALLATION:
NOTE: See the Electrical Connections Reference
Guide section of the instruction manual for detailed
photos of each part and their respective connections.
7. Position th roll r/contactor sub-ass mbly into th front
bump r as shown. Fast n th sub-ass mbly into front
bump r using th M8 bolts (it m #3) and M8 locknuts
(it m #17). (S illustrations 1-6, 1-7 and 1-8).
8. Tight n to sp cification.
Ill. 1-5
R ar f nd r cov r
WARNING
ALWAYS disconn ct black n gativ (-) cabl
from batt ry FIRST. Failur to do so will r sult
in high curr nt l ctrical arc, and may r sult in
batt ry xplosion if tool touch s ground d
fram . D ath or s rious injury may occur.
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Ill. 1-6
Ill. 1-8
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
Ill. 1-7
Roll r/
Contactor
sub-assy
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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON WINCH
INSTALLATION (continued):
9. Unspool a short portion of th cabl from th winch
mount sub-ass mbly as shown. (S illustration 1-9).
10. Position th winch/mount sub-ass mbly into th bump r
and align into th roll r/contactor sub-ass mbly as
shown. Align th r ar upp r tabs of winch/mount sub-
ass mbly into th bump r and t mporarily ins rt M8
bolts (it m #3) into th hol s, this will h lp k p th
mounts align d into th bump r. (S illustrations 1-9,
1-10, 1-11 and 1-12).
11. Fast n th winch/mount sub-ass mbly to th roll r/
contactor sub-ass mbly using th M8 bolts (it m #3)
ins rt d into th thr ad hol s as shown. Tight n to M8
sp cification. (S illustrations 1-11, 1-12 and 1-13).
Ill. 1-9
Ill. 1-10
Ill. 1-12
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
Ill. 1-11
Winch /
Mount
sub-assy
3
Thr ad d
hol s
Ill. 1-13
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Roll r/
contactor
sub-assy
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Upp r r ar tabs

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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON WINCH
INSTALLATION (continued):
12. Rout th cabl rop thru th roll r fairl ad and attach
th cl vis hook (it m #6) onto th thimbl nd as shown
and if quipp d, th rubb r bump r (it m #14). Th
winch cabl n ds to b rout d thru th roll r fairl ad
off th top . (S illustrations 1-14 and 1-15).
13. Th blu and y llow conn ctions cabl s can now b
rout d and fast n d to th winch motor t rminals.
Ch ck and confirm wir routing and conn ctions ar as
shown and mak n c ssary adjustm nts b for moving
to n xt v hicl installation st ps. (S illustrations 1-14,
1-16 and 1-17).
Ill. 1-14
Ill. 1-15
Ill. 1-17
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Rop
routing
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Ill. 1-16
Us this routing clip for blu /y llow.
Clos two wir s and trim xc ss ti .
Us this routing clip for r d/black.
Clos two wir s and trim xc ss ti .
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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON WINCH
INSTALLATION (continued):
14. Install front bump r-winch ass mbly onto th
v hicl fram using th long r M8 bolts (it m
#3) for th two upp r bump r locations as
shown. R -install th low r OEM M8 scr ws and
OEM M6 should r scr ws. R -install th rack
mounting M8 bolt and nut. R install th plastic
ngin guard. (S illustrations 1-18, 1-19, 1-20,
1-21 and 1-22). Note, the plastic engine guard
can be flexed downwards to provide install
access.
15. Tight n all fast n rs to sp cifications.
Ill. 1-18
Plastic
ngin
guard
Ill. 1-21
Ill. 1-19
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
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Ill. 1-20
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Low r OEM
scr ws
Bump r-rack
mounting
6MM FASTENER TORQUE:
7 ft. lbs. (9.5 Nm)
Ill. 1-22
FRONT
FRONT

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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON WINCH
INSTALLATION (continued):
16. Ch ck that all wir s ar fr to mov and not
pinch d b tw n th v hicl chassis and th
winch ass mbly.
17. Rout th black (it m #10) and r d (it m #11)
pow r cabl s towards th right, in front of th
radiator grill c nt r cov r as shown. Continu
routing th r d and black cabl s up ov r th
front shock and th n along xisting wiring
bundl back towards th batt ry. Attach cabl s
to chassis fram at r quir d locations using
cabl ti s (it m #2). (S illustrations 1-23,
1-24,1-25, and 1-26).
Note, do not connect the
winch cables to the battery at this time.
Ill. 1-23
Front
right
shock
Ill. 1-25
Ill. 1-24
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Ill. 1-26
2
Batt ry
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2
FRONT
Rout along
right sid of
fram

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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON
HANDLEBAR SWITCH INSTALLATION:
NOTE: See the Electrical Connections
Reference Guide section of the instruction manu-
al for detailed photos of each part and their re-
spective connections.
18. Using th suppli d scr ws, install th winch
control handl bar switch (it m #1) to th v hicl
l ft handl bar and rout th wir harn ss as
shown. Torqu scr ws to th sp cification list d,
b ing car ful not to ov rtight n. (S illustrations
1-27 and 1-28).
19. Conn ct th whit harn ss conn ctor of th
switch harn ss (it m #1) to th winch contactor
conn ctor as shown. (S illustration 1-29).
20. R mov th radiator cap lid and rout th r d
nd (12V acc ssory pow r) of switch harn ss to
ar a und r front rack. R mov th dummy cap or
acc ssory sock t harn ss from th DLC 4P r d
conn ctor as shown. Conn ct th switch harn ss
(it m #1) into th DLC conn ctor and if quipp d,
conn ct th oth r nd to th acc ssory sock t
harn ss, so 12V acc ssory pow r can b us d at
sam tim of winch op ration. S cur winch
harn ss to v hicl using cabl ti s (it m #2).
(S illustration 1-30).
RANCHER / FOREMAN / RUBICON FINAL
INSPECTION:
21. Confirm that all wiring is corr ct.
22. Confirm that th r ar no xpos d wir s or t rminals.
23. All loos wir s n d to b wrapp d tight, and s cur d
away from moving parts and h at sourc s.
Ill. 1-27
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Ill. 1-28
Us xisting cabl ti
SWITCH SCREW FASTENER
TORQUE:
2 ft. lbs. (2.7 Nm)
Switch
mount
clamp
Winch control
switch mount d
Rout winch control switch
harn ss down thru h adlight
pod / handl bar cov r
Ill. 1-29 Contactor
Conn ctor
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© 2019 Kolpin Outdoors Inc. REV 00
RANCHER / FOREMAN / RUBICON
REINSTALLATION:
24. R install th radiator cap cov r on v hicl .
25. R install r d and black cabl s to batt ry
t rminals along with winch pow r cabl s (it ms
#10 and #11) using OEM scr ws as shown. (S
illustration 1-26).
26. R install th r ar f nd r cov r, tank cov r and
s at on th v hicl that w r pr viously r mov d
in st p 4.
27. With v hicl k y in th ON position, ch ck winch
for prop r op ration.
HANDLEBAR SWITCH OPERATION:
Wh n prop rly install d, th handl bar switch allows you to
op rat th winch whil s at d on th v hicl . Prop r switch
op ration is shown. (S illustration 1-31).
For additional assistanc , pl as contact Kolpin custom r s rvic d partm nt at
[phone] or [phone] or mail custom rs rvic @kolpin.com
Five Year Mechanical Limited Warranty and Three Year Electrical Limited Warranty
For th p riod of fiv (5) y ars from th purchas dat , Kolpin will r plac for th original purchas r, fr of charg , any m chanical
part or m chanical parts found upon xamination by Kolpin to b d f ctiv in mat rial, workmanship, or both. For th p riod of thr
(3) y ars from th purchas dat , Kolpin will r plac for th original purchas r, fr of charg , any l ctrical part or l ctrical parts
found upon xamination by Kolpin to b d f ctiv in mat rial, workmanship, or both.
All transportation costs incurr d submitting product to Kolpin for warranty consid ration must b born by th purchas r. If Kolpin
d t rmin s that th product must b r turn d to th factory for cr dit, pl as call 1-877-956-5746 for a R turn M rchandis
Authorization (RMA) numb r and shipping instructions.
This warranty do s not apply to parts that hav b n damag d by accid nt, alt ration, abus , improp r maint nanc , normal w ar, or
oth r caus s b yond th manufactur r’s control. In ord r to prot ct you and your ATV, c rtain parts of th winch/plow syst m and/or
hardwar ar d sign d to fail wh n th quipm nt is ov r-str ss d. Parts that ar lost du to loos ning and improp r maint nanc
ar not cov r d und r warranty. This warranty do s not cov r r moval or r installation labor f s of th winch/plow syst m and
r lat d compon nts.
P riph ral products such as ngin s, l ctric motors, and actuators may carry an original manufactur r’s warranty. Most hardwar is
g n ral in natur and is asily obtain d locally. B sur to r plac with minimum m tric class 8.8 sp cification.
Kolpin Outdoor , Inc.
www.kolpin.com
Ill. 1-31
R d Datalink
conn ctor 4P
Ill. 1-30
Dummy cap
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© 2019 Kolpin Outdoors Inc. REV 00
TROUBLESHOOTING
If your winch is not functioning prop rly, b low is a short guid that can h lp you diagnos and corr ct th probl m.
NOTE
For furth r t chnical support, contact our h lp lin at
1-877-956-5746.
Symptom Po ible Cau e Recommended Solution
Winch will not
op rat
Contactor not r c iving pow r Turn v hicl k y on.
Conn ctions b tw n compon nts not in
prop r ord r
Ch ck conn ctions. Conn ct wir d handl bar switch
conn ction from v hicl main wir harn ss dir ctly to
contactor to mak sur a dir ct conn ction will op rat th
winch. If conn ctions ar not in th ord r shown in th pictur s
in th last pag , th whol syst m may not function or only
c rtain parts of it will function.
Loos batt ry cabl conn ctions Tight n nuts on all cabl conn ctions.
K y d pow r circuit (orang wir s) not
prop rly pow r d
Ch ck fus box for 10A acc ssory circuit. Ch ck voltag in
c rtain plac s, sp cially orang wir s coming out of th main
harn ss by th st ring post.
Contactor malfunctioning
Tap contactor to loos n contacts. Apply 12 volts to coil
t rminals dir ctly. A clicking indicat s prop r activation.
D f ctiv switch ass mbly R plac switch ass mbly.
D f ctiv motor
Ch ck for voltag at armatur port with switch pr ss d. If
voltag is pr s nt, r plac winch ass mbly.
N st d and bound d cabl within winch
ass mbly
Mov fr spool knob to th “fr spool” position. Manually pull
cabl out of winch until nd is m t and th n r -spool cabl
back into winch.
Wat r has nt r d motor
Allow to drain and dry. Run in short bursts without load until
compl t ly dry.
Contactor pow r d, but not winch
If you can h ar a clicking sound wh n you pr ss th winch
control but th winch do s not mak any sounds, ch ck th
conn ctions b tw n th winch and th contactor.
Winch not in prop r g ar
Mov fr spool knob to th "lock d spool" position, th n
r ch ck. If probl m p rsists, a qualifi d t chnician n ds to
ch ck and r pair.
Winch
op rat s too
slowly
Insuffici nt curr nt or voltag
Th batt ry is w ak, r charg . Run winch with v hicl motor
running (batt ry should hav a strong charg ).
Loos or corrod d batt ry cabl
conn ctions
Cl an, tight n, or r plac .
Winch
ov rh ating
Winch running tim too long Allow winch to cool down p riodically.
Winch
op rat s in
on dir ction
only
D f ctiv or stuck contactor
Tap contactor to loos n contacts.
R pair or r plac contactor.
D f ctiv switch ass mbly R plac switch ass mbly.
D f ctiv brak ass mbly R plac winch ass mbly.
Winch mak s
nois but rop
do s not mov
Winch improp rly load d Ch ck that th winch is cl ar and th rop is not bound up and
Note: If any hardware is missing, do not
return to the store. Call us to help, Toll Free
1-877- 56-5746.

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© 2019 Kolpin Outdoors Inc. REV 00
ELECTRICAL CONNECTION REFERENCE GUIDE:
Winch with Roll r Fairl ad and Handl bar Switch
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To v hicl
batt ry
pow r
Conn ct
harn ss s
tog th r
To v hicl data link
conn ctor (4P R d)
To acc ssory sock t
harn ss (if quipp d)