Kolpin Outdoors 25-9 Series Installation and operating instructions

© 2023 Kolpin Outdoors Inc. REV 00
WINCH MOUNT KIT
FOR POLARIS RZR XP 1000
P/N 25-3440
ASSEMBLY / OWNERS MANUAL
Application
WINCH KIT NO. 25-xxx
Before you begin, please read these instructions and check to be sure all parts and tools are
accounted for. The following instructions contain details required to install and service the contents
of this kit.

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© 2023 Kolpin Outdoors Inc. REV 00
OPERATING INSTRUCTIONS
Congratulations! You’ve just purchased the most durable accessory component in the industry. Our accessories work
great all year round! With proper care and maintenance, your Kolpin accessory will last for years to come! Please read
and understand all assembly instructions, notices and warnings before assembling and using your Kolpin accessory.
Fo ow these guide ines to ensure a successfu and satisfactory insta ation:
Read, understand this manual before beginning installation
Periodically check for wear and tightness of all fasteners.
Replace or re-torque fasteners as necessary.
SAFETY & GENERAL PRODUCT INFORMATION
Kolpin accessories are designed with your safety in mind.
In order to protect you and your vehicle, certain parts of the accessory and/or hardware may be designed to collapse or
break when the equipment is over-stressed.
Kolpin winch mount kits are designed to be compatible with Kolpin and Cycle Country winches along with many others,
but may not be compatible with some winches. Kolpin winch mount kits have design features that benefit snow plow ap-
plications.
! DANGER ! ! WARNING ! ! CAUTION !
To avoid persona injury or damage to your vehic e:
Read and understand all notices for:
Caution
Warning
Danger
Follow instructions for your vehicle, winch, winch mount and other items used in combination with this product.
Do not winch unsecured loads at any time.
Disconnect battery during winch installation or service to prevent electrical hazards.
Do not lift loads overhead.
Do not exceed the load capacity of the winch.
Always wear gloves when handling wire winch cable.
Do not use your winch or winch mount for towing.
Do not shock load the winch, cable or winch mount.
Keep fingers, hands and loose clothing away from roller fairlead and winch cable drum when in use.

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© 2023 Kolpin Outdoors Inc. REV 00
Kit Contents:
Item Qty Part Description Part Number
11RZR Winch Mount Bracket -
32Hex Flange Locknut, Zinc Plated, M10-1.5 -
46Flange Hex Bolt, Zinc Plated, M10-1.5 x 30mm LG -
52Carriage Screw, Zinc Plated, M10-1.5 x 30mm LG -
61Instruction Guide (not shown) -
21RZR Winch Skid Bracket -
4
5
1
2
3

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© 2023 Kolpin Outdoors Inc. REV 00
BEFORE YOU BEGIN:
• Your Ko pin accessory is exc usive y designed for
your vehic e
• P ease read and understand a instructions
• Verify a parts and too s are accounted for
• To ensure a satisfactory insta ation, fo ow a
steps correct y and in the sequence described
• Keep these instructions for future reference or for
informationa requests
• To faci itate insta ation, make sure that your
vehic e is c ean and free of debris
• A directions referring to right and eft are when
the rider is sitting on the machine
TOOLS REQUIRED:
• Metric wrench set
• Metric socket set
• Torx socket set
• Torque Wrench
• P iers
• Do not use impact too s to insta
hardware
APPROXIMATE ASSEMBLY TIME: 30 minutes
Note: Additional time may be required to accommodate other installed accessories.
Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free
1-877-56-5746.
Mount bracket (item #1) has pre-drilled holes for mount-
ing Kolpin contactor (provided with winch kit) onto back-
side of bracket as shown in images below and to the
right. Note: Contactor M6-1.0 x 10mm LG screws are not
included

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© 2023 Kolpin Outdoors Inc. REV 00
RZR PREPARATION:
1. Shift vehicle transmission into “PARK”. Turn ignition
key to “OFF” position and remove from vehicle ignition.
2. Remove driver seat by pulling strap to disengage seat.
Tilt forward and remove from vehicle. (See illustration
1-1).
3. Disconnect black negative (-) cable from battery first,
then disconnect red positive (+) cable from battery.
(See illustration 1-2).
4. Remove the front lower fascia by removing the two
screws and two bolts shown. (See illustration 1-3).
5. Remove the upper fascia plastic cover that surrounds
lower portion of front bumper by removing the plastic
push rivets from each side. Removal allows easier
access install winch assembly to vehicle. Save parts for
reinstall later. (See illustrations 1-3 and 1-4).
Ill. 1-2
Ill. 1-3
WARNING
ALWAYS disconnect black negative (-) cable from
battery FIRST. Failure to do so will result in high
current electrical arc, and may result in battery
explosion if tool touches grounded frame. Death or
serious injury may occur.
!
!
Ill. 1-1
Strap
Ill. 1-4
Lower fascia
Upper fascia
Push rivet

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© 2023 Kolpin Outdoors Inc. REV 00
RZR PREPARATION (continued):
6. Remove the front drive protection plate and tow strap
by removing the four bolts. (See illustration 1-5).
7. Remove the center hood by removing the two screws
and remove hood towards the rear. Save parts for
reinstall later. (See illustration 1-6).
8. Remove the center instrument panel by removing the
two screws as shown. Lift up and remove center
instrument panel. Save parts for reinstall later. (See
illustration 1-7).
RZR WINCH INSTALLATION:
. Locate the upper winch mounting holes on vehicle
frame and install two M10 bolts (item #4). Loosely
install bolts into frame leaving 4-5 threads exposed.
(See illustrations 1-8 and 1-). Note, starting the bolts
halfway installed is needed for next step of
installing winch assembly.
Ill. 1-6
Ill. 1-7
Ill. 1-5
Ill. 1-8
Ill. 1-
4

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© 2023 Kolpin Outdoors Inc. REV 00
RZR WINCH INSTALLATION
(continued):
10. Place winch mount bracket (item #1)
onto the M10 hex flange bolts (item
#4) previously installed as shown.
Install two more M10 hex flange
bolts and tighten all to specification.
(See illustration 1-10).
11. Install winch to mounting bracket
using the M8 hardware supplied with
winch kit as shown (bolts, lock washers,
flat washers). Tighten M8 hardware to
specification. (See illustration 1-11).
12. Pull the winch rope thru the opening in the
top mounting bracket as shown. (See
illustration 1-12).
13. The 25-3440 mounting bracket kit fits both
Wide Roller Fairleads and Narrow Roller
Fairleads. The following steps will guide
through installing both types.
Ill. 1-11
Winch
Ill. 1-10
Ill. 1-12
10MM FASTENER TORQUE:
34 ft. lbs. (46 Nm)
1
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
4
M8 hardware
included with
winch kit

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© 2023 Kolpin Outdoors Inc. REV 00
RZR WINCH INSTALLATION (continued):
14. For installing wide roller fairlead, use the
M10 carriage screws (item #5) and M10
locknuts (item #3) included in mounting kit.
Note: Wide roller fairlead is not included
in kit, sold separately, PN 85 87. For
using narrow roller fairlead, see step 22,
yet follow below steps for installing
lower winch skid bracket (item #2).
15. Loosely install the two M10 carriage screws
(item #5) thru the rear side of the upper
bracket square holes as shown. (See
illustration 1-13).
16. Install lower mounting bracket skid plate
(item #2) below the winch. Make sure the
tab on the bottom of the plate fits into the
slot in the front chassis. The upper hole
slots will align with carriage screws and
allow screws to fit thru facing towards front.
(See illustrations 1-14 and 1-15).
17. Loosely install two M10 bolts (item #4) into
the lower holes. (See illustrations 1-14 and
1-15). Note, do not tighten fasteners at
this step.
18. Pull the winch rope thru the lower plate
opening as shown. (See illustration 1-14).
Ill. 1-13
5
Ill. 1-14
5
2
4
Ill. 1-15
4
Slot in front
chassis

© 2023 Kolpin Outdoors Inc. REV 00
RZR WINCH INSTALLATION (continued):
1 . Install the wide roller fairlead onto the carriage
screws and fasten using M10 locknuts (item #3).
(See illustrations 1-16 and 1-18). Note, make
sure that the bigger roller is positioned on the
bottom.
20. Tighten all M10 fasteners to specification. (See
illustrations 1-16 and 1-18).
21. For installing narrow roller fairlead, use the M8
fasteners (included in winch kit). The M8 screws
will fit through lower set of holes as shown. Tighten to
M8 fastener specification. Note: The M1 carriage
screws included in mounting kit will not be
used with narrow roller fairlead installation.
22. Route the rope cable thru the roller fairlead and
attach the clevis hook and rubber bumper (if
included with winch kit) onto the thimble end as
shown. (See illustration 1-18).
Ill. 1-16
10MM FASTENER TORQUE:
34 ft. lbs. (46 Nm)
3
Ill. 1-17
Ill. 1-18
Winch
8MM FASTENER TORQUE:
17 ft. lbs. (23 Nm)
M8 hardware
included with
winch kit

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© 2023 Kolpin Outdoors Inc. REV 00
Winch Cab e Wrap Insta ation on Spoo Drum:
23. The winch cable or rope should be wrapped around the spool drum as
shown. Spooling the cable as shown will prolong cable life and en-
hance winch performance. (See illustration 1-1 ).
Winch Wiring and Connections:
24. Using the winch kit instructions, route and connect the electrical cables
and components for the winch system.
25. Route red and black power cables (included in winch kit) from winch
assembly up through front gearcase area, up along radiator left side
towards hood opening as shown. Use cable ties (included with winch
kit) to secure the harness. (See illustrations 1-20, 1-21 and 1-22).
26. Continue routing red and black harness cables up and
over the front left upper radiator support as shown. Se-
cure cable bundle with plastic cable tie. (See illustration
1-21).
27. Route red and black cables down towards dash wall
grommet. (See illustration 1-22).
28. Route red and black cables through the grommet in the
front floor panel and up to the pulse bar area. Secure
wire bundle with plastic cable tie as shown. (See
illustration 1-22).
2 . Remove M6 nuts from the negative and positive Pulse
bar stud terminals. Save for reinstall later.
30. Install the winch red and black power cable connections
to the Polaris Pulse Bar terminals with the two M6 nuts
previously removed. Tighten to specification.
31. Secure all harnesses using cable ties (provided with
winch kit) to prevent contact with hot components, sharp
edges or moving parts.
Ill. 1-1
Ill. 1-20
Contactor
connector
Red & Black
Power Cables
Ill. 1-21
Radiator
Upper Support
M6 NUT PULSE BAR FASTENER
TORQUE:
44 in. lbs. (5.0 Nm)

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© 2023 Kolpin Outdoors Inc. REV 00
RZR FINAL INSPECTION:
32. Confirm that all wiring is correct.
33. Confirm that there are no exposed
wires or terminals.
34. All loose wires need to be wrapped
tight, and secured away from moving
parts and heat sources.
RZR REINSTALLATION:
35. Reconnect the red (positive) and black
(negative) cables to battery terminals
at this time using original hardware.
36. Re-install the seat.
37. Re-install the center hood.
38. Re-install the center instrument panel
3 . Connect the corded winch remote switch (item #22) to
the dash socket.
40. With vehicle key in the ON position, check winch for
proper operation.
41. Retighten all hardware after 30 minutes of riding.
Ill. 1-24
Ill. 1-25
Ill. 1-26
Ill. 1-27
Ill. 1-22
Grommet
in the
front floor
panel
Red and
Black Cables
Ill. 1-23
Cable tie
included
with winch
kit
Pulse bar

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© 2023 Kolpin Outdoors Inc. REV 00
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 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 1-877-56-5746 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 accessory system and/or hardware are designed to
fail when the equipment is over-stressed. Parts that are lost due to loosening and improper mainte-
nance are not covered under warranty. This warranty does not cover removal or reinstallation labor
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 obtained locally. Be sure
to replace with minimum metric class 8.8 specification.
Ko pin Outdoors, Inc.
Te ephone: (763)-478-5800
To Free: (877)-956-5746
Fax Number: (800)-245-7569
www.ko pin.com
Emai : customerservice@ko pin.com