Kolpin Outdoors 26-3040 Installation and operating instructions

QUICK-MOUNT WINCH KIT
Assembly / Owner’s Manual
APPLICATION: 2022 RANGER /RANGER CREW
Verify accessory fitment at Kolpin.com
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P/N 26-3040
POLARIS RANGER™ QUICK-MOUNT 3500
LB WINCH KIT

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INTRO
Thank you for purchasing Kolpin®engineered products. With proper installation, usage, care, and maintenance,
your Kolpin®product will last for years to come.
BEFORE YOU BEGIN
• Read and understand the entire installation manual, including all installation instructions, operating
instructions, safety warnings and guidelines before installing or operating your accessory. Failure to comply
may result in damage to the product and / or vehicle, and can lead to hazards up to and including death.
• Verify all parts and tools are accounted for. If parts are missing, do not return to the store. Call us for help, Toll
Free 1-877-956- 5746
• Follow all steps correctly and in the sequence described.
• Keep these instructions for future reference or for informational requests.
• To facilitate installation, make sure that your vehicle is clean and free of debris.
• All directions referring to right and left are from the rider perspective when sitting on the machine.
IMPORTANT
You must order Power Cables Kit 85095 separately to connect the battery to the contactor for models:
• 2022 RANGER CREW 570
ASSEMBLY TIME
Approximately 30 minutes
SAFETY INFORMATION
Please read and understand all assembly instructions, notices and warnings before assembling and operating
your Kolpin winch system.
Follow these guidelines to ensure satisfactory operation:
• Read this manual and your ATV / UTV operators manual before use.
• Periodically check for wear and tightness of all fasteners. Replace or re-torque fasteners as necessary.
TOOLS REQUIRED
• Safety Glasses
• Cutting Tool
• Drill
– 1 in (25 mm)
– 5/32 in (4 mm)
• Pliers
• Socket Set, Metric
• Torque Wrench
• Wrench Set, Metric

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KIT CONTENTS
REF QTY PART DESCRIPTION PART NUMBER
1 2 BRKT-Mount Backer 25-3430
2 1 Remote, Switch, 4500 85067
3 1 ASM-Winch, 3500 INTG n/a
4 1 INSTR-INTG 3500 SYN Winch Kit n/a
5 1 Wire-Harness n/a
6 1 Ranger Dash Harness n/a
71 Strap, Winch, Hook, Kolpin, Orange 85071
8 1 Winch Stop 85080
9 1 Roller-Fairlead, Winch 4500 85087
10 1 Switch-Winch 25-0700
11 4 Cable-Tie, 25-76MM, WEATH. -RES. 7080492
12 2 SCR- #10x3/4-HI/LO-PN-T25, TRX-M 7512026
13 4 SCR- HXFL-M10 x 1.5 x 20 8.8 Z NYL 7518460
14 2 SCR-RHCAR-M10 x 1.5 x 25 8.8 ZOD 7519372
15 2 NUT-M10 x 1.5 HFN NYLOC ZOD 7547423
16 2 Washer-M5, Flat 7556724
17 1 Promo Decal n/a
18 1 Roller Hawse Hook RPR0108

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WINCH DETAIL
REF QTY PART DESCRIPTION PART NUMBER
1.1 1 BRKT-Mount, Winch 25-3430
1.2 1 Replacement Winch 3500# 25-9350R
1.3 1 Synthetic Rope, Kolpin Brand 2500/3500 85065
1.4 1 Contactor 85068
1.5 1 Cable-Winch, Yellow 6 GA, 120mm n/a
1.6 1 Cable-Winch, Blue 6 GA, 230mm n/a
1.7 1 Cable-Power, Winch, Black #6 1651mm n/a
1.8 1 Cable-Power, Winch, Red #6, 1651mm n/a
1.9 2 SCR-TFHFL M6 x 1.0 x 15 CHS BLK 7518513
1.10 4 SCR-TXTH-M8 x 1.25 x 20 8.8 ZODP30 7519260

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INSTALLATION INSTRUCTIONS
VEHICLE PREPARATION
GENERAL
1. Park the vehicle on a flat surface.
2. Shift the vehicle into PARK.
3. Turn the key to the OFF position and remove the
key.
4. Flip up and/or remove the passenger’s seat
bottom and remove the under seat storage
compartment tray (if applicable) by pulling it in
upward direction.
5. Disconnect the black negative (-) cable from the
battery, then disconnect the red positive (+) cable
from the battery.
WARNING
ALWAYS disconnect black negative (-) cable from
the battery FIRST. Failure to do so will result in high
current electrical arc, and may result in battery
explosion if a tool touches the grounded frame.
Death or serious injury may occur.
6. Remove the front bumper by removing the four
bolts (two upper and two lower) as shown. Retain
the bolts for reuse.
NOTICE
The bumper is heavy. Provide adequate support
before removing screws.
7. Unlatch the two hood latches to remove the hood.
8. Remove the eight plastic tuflock rivets securing the
driveshaft cover to the floor. Save the fasteners for
use during reinstallation. Remove the driveshaft
cover from vehicle.
9. Remove the winch assembly from the packaging.

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ACCESSORY INSTALLATION
WINCH INSTALLATION
1. Place the winch sub assembly onto the bumper of
the vehicle.
2. Insert the four screws fthrough the mount and
bumper.
3. Fasten the four screws fusing the two nut
brackets q. Torque to specification.
TORQUE
Nut Bracket Screws:
34 ft-lbs (46 N·m)
4. Install the roller fairlead oto the vehicle bumper
using the two M10 carriage screws g.
5. Feed the rope through the roller fairlead.
6. Fasten the screws gusing the M10 locknuts h.
Torque to specification.
TORQUE
Roller Locknuts:
34 ft-lbs (46 N·m)
7. Install the rubber bumper i, hook l, and strap u
onto the rope thimble end loop.

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8. Locate the red and black wires on the winch
assembly. If the wires are secured in a bundle with
a plastic tie, cut the tie to allow the cables to be
routed through the frame.
9. Reinstall the front bumper with the four retained
bolts. Loosely install all bolts before tightening to
specification.
IMPORTANT
Make sure no wires are pinched between the joining
parts.
TORQUE
Bumper Bolts:
30 ft-lbs (41 N·m)
10.Route the red and black battery cables up along
the front frame over the front shock 1(, then down
the cab wall 2) towards the center floor 2! along
the existing factory wire harness. The black and
red battery leads route and follow the main factory
harness to the battery compartment 2@. Use zip
ties 2# to secure the harness.
IMPORTANT
Do not connect the cables to the battery and bus bar
terminals at this time.

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11. Verify the wire routing to make sure the red and
black cables are secured away from any moving or
potentially hot parts.
12.Reinstall the driveshaft floor cover using the eight
plastic tuflok rivets previously removed.
REMOTE AND SWITCH INSTALLATION
1. Remove the top center dash cover (cup holder) of
the vehicle by removing the two plastic tuflock
push rivets.
2. Connect the contactor to the vehicle harness 2$
using the wire harness t.

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3. Connect the switch harness (dash harness) yto
the vehicle plug connector near the cab wall.
4. Route the switch harness (dash harness) y
through the dash to the switch panel location. The
switch harness (dash harness) should be secured
with a zip tie to the main vehicle harness.
5. Cut out the dash pattern using the provided
dimensions.
IMPORTANT
The pattern on the dash panel may not match the
switch. Use the provided dimensions.
6. Install the dash switch into the panel cutout.

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7. Connect the switch harness (dash harness) yto
the dash switch.
IMPORTANT
Wires must be connected in the order shown.
• Top “Out” – Green wire
• Middle – Red wire
• Bottom “In” – Black wire
8. Locate the corded remote socket location in the
glovebox.
9. Drill a center 1 inch hole.
10.Install the harness socket into the drilled hole.
11. Mark the screw holes.
12.Drill the screw holes with a 5/32 inch (4mm) bit.
13.Install the two screws dand two washers jto
attach the remote to the glovebox. Tighten the
screws until fully seated.

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14.Connect the switch harness (dash harness) yred
wire to the remote switch harness wred wire.
15.Put the remote harness wdown through the
vehicle by the winch.
16.Connect the winch harness tto the winch
contactor harness .
17.Secure the winch harness tto the frame with a
zip tie 2#.
VEHICLE REASSEMBLY
1. Confirm all the wiring is correct and there are no
exposed wires or terminals.
2. Tightly wrap all loose wires and secure all wires
away from moving parts and heat sources.
3. Connect the positive and negative battery cables
as shown in the Owner’s manual.
WARNING
When BOTH battery cables are disconnected
ALWAYS connect AND tighten the red positive (+)
battery cable FIRST. Failure to comply will result in a
high current electrical arc that may result in battery
explosion if a tool touches the grounded frame.
Death or serious injury may occur.
4. Reinstall the seat, the center dash panel, and the
hood.
5. With the vehicle key ON, test the winch operation.

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CONTROL SWITCH OPERATION
When properly installed, the control switches allow
you to operate the winch while seated in the vehicle
using the dash switch or remotely using the corded
switch. Proper switch operation is shown.
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION
Winch will not operate. Contactor not receiving power. Turn vehicle key ON.
Connections between components not in
proper order.
Check connections. Connect wired
handlebar switch connection from
vehicle main wire harness directly to
contactor to make sure a direct
connection will operate the winch. If
connections are not in the order shown
in the pictures on the last page, the
whole system may not function, or only
certain parts of it will function.
Loose battery cable connections. Tighten nuts on all cable connections.
Keyed power circuit (orange wires) not
properly powered.
Check fusebox for 10A accessory circuit.
Check voltage in certain places,
especially orange wires coming out of
the main harness by the steering post.
Contactor malfunctioning. Tap contactor to loosen contacts. Apply
12 volts to coil terminals directly. A
clicking indicates proper activation.
Defective switch assembly. Replace switch assembly.
Defective motor. Check for voltage at armature port with
switch pressed. If voltage is present,
replace winch assembly.
Nested and bounded cable within winch
assembly.
Move free spool knob to the “free spool”
position. Manually pull cable out of winch
until end is met and then re-spool cable
back into winch.
Water has entered motor. Allow to drain and dry. Run in short
bursts without load until completely dry.
Winch makes noise,
but rope does not
move.
Contactor powered, but not winch. If you can hear a clicking sound when
you press the winch control, but the
winch does not make any sounds, check
the connections between the winch and
the contactor.

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Winch not in proper gear. Move free spool knob to the “locked
spool” position, then recheck. If problem
persists, a qualified technician needs to
check and repair.
Winch operates too
slowly.
Winch improperly loaded. Check that the winch is clear and the
rope is not bound up.
Insufficient current or voltage. The battery is weak, recharge. Run
winch with the vehicle motor running
(battery should have a strong charge).
Loose or corroded battery cable
connections.
Clean, tighten, or replace.
Winch overheating. Winch running time too long. Allow winch to cool down periodically.
Winch operates in one
direction only.
Defective or stuck contactor. Tap contactor to loosen contacts.
Repair or replace contactor.
Defective switch assembly. Replace switch assembly.
Defective brake assembly. Replace winch assembly.
ELECTRICAL CONNECTION REFERENCE GUIDE

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WARRANTY
FIVE YEAR MECHANICAL LIMITED WARRANTY AND THREE YEAR
ELECTRICAL LIMITED WARRANTY
For the period of five (5) years from the purchase date, Kolpin will replace for the original purchaser, free of
charge, any mechanical part or mechanical parts found upon examination by Kolpin to be defective in material,
workmanship, or both. For the period of three (3) years from the purchase date, Kolpin will replace for the
original purchaser, free of charge, any electrical part or electrical parts found upon examination by Kolpin to be
defective in material, workmanship, or both.
All transportation costs incurred submitting product to Kolpin for warranty consideration must be borne by the
purchaser. If Kolpin determines that the product must be returned to the factory for credit, please call 1-877-956-
5746 for a Return Merchandise Authorization (RMA) number and shipping instructions.
This warranty does not apply to parts that have been damaged by accident, alteration, abuse, improper
maintenance, normal wear, or other causes beyond the manufacturer’s control. In order to protect you and your
ATV, certain parts of the winch/plow 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 labor fees of the winch/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 obtained locally. Be sure to replace with minimum
metric class 8.8 specification.
Kolpin Outdoors, Inc.
Telephone: [phone]
Toll Free: (877)-956-5746
Fax Number: (800)-245-7569
www.Kolpin.com
Email: [email protected]