Kolpin Outdoors KAWASAKI MULE QUICK-MOUNT 4500 Installation and operating instructions

QUICK-MOUNT WINCH KIT
Assembly / Owner’s Manual
APPLICATION: Kawasaki MULE™Pro-FX / FXT / FXR /
DX / DXT
Verify accessory fitment at Kolpin.com
Instr 26-2000 Rev 01 2020-09 Page 1 of 12
P/N 26-2000
KAWASAKI MULE™QUICK-MOUNT 4500
LB WINCH KIT

Instr 26-2000 Rev 01 2020-09 Page 2 of 12
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, and safety warnings and guidelines before installing or operating your accessory. Failure to
comply may result in damage to the product, damage to the 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
• To ensure a satisfactory installation, 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 when the rider is sitting on the machine.
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.
ASSEMBLY TIME
Approximately 42 minutes
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

Instr 26-2000 Rev 01 2020-09 Page 3 of 12
KIT CONTENTS
REF QTY PART DESCRIPTION PART NUMBER
1 1 Winch Assembly – 4500 lb n/a
2 1 3-Wire Splitter n/a
3 1 Winch Switch 25-0700
4 1 UTV Dash Switch Harness n/a
5 1 Remote Switch n/a
6 2 Screw – Torx®Pan Head HI/LO, 10 x 3/4 7512026
72 Washer – Flat, M5 7556724
8 10 Cable Tie 7080492
9 2 Winch Bracket n/a
10 4 Nut – Hex Flange, M10 x 1.5 7547423

Instr 26-2000 Rev 01 2020-09 Page 4 of 12
WINCH DETAIL
REF QTY PART DESCRIPTION PART NUMBER
1.1 1 Kolpin®Winch Strap, Orange 85071
1.2 1 Roller Hawse Hook RPR0108
1.3 1 Winch Stop 85080
1.4 1 Kolpin®Synthetic Rope 85064
1.5 1 Winch 4500 lb 25–9450R
1.6 1 Cable – Winch, Blue 6 GA (241 mm) n/a
1.7 1 Cable – Winch, Yellow 6 GA (241 mm) n/a
1.8 1 Cable – Power, Red 6 GA (2184 mm) n/a
1.9 1 Cable – Power, Black 6 GA (2197 mm) n/a
1.10 1 Contactor 85068
1.11 2 Screw – Socket Head, M6 x 1 x 10 7517337
1.12 1 Bracket Mount, Winch n/a
1.13 2 Nut – Hex Flange, M10 x 1.5 7547423
1.14 4 Screw – Hex Flange, M8 x 1.25 x 20 n/a
1.15 1 Fairlead Roller, Winch 4500 lb 85087
1.16 2 Screw – Round Head Carriage, M10 x 1.5 x 25 7519372

Instr 26-2000 Rev 01 2020-09 Page 5 of 12
INSTALLATION INSTRUCTIONS
VEHICLE PREPARATION
GENERAL
1. Park vehicle on a flat surface.
2. Shift vehicle transmission to NEUTRAL and set
parking brake.
3. Turn key to OFF position and remove key from
vehicle.
4. Remove and keep one left side and one right side
bumper bolt and nut.
5. Remove and keep three bottom bumper bolts.
Remove and set aside bumper.
6. Remove and set aside seat.
7. Disconnect battery as shown in Owner’s Manual.
ACCESSORY INSTALLATION
WINCH INSTALLATION
1. Make sure wire routing and connections are as
shown and make necessary adjustments.
2. Put red and black cables up through frame
opening and over front gear case along the
parking brake cable bundle.
3. Attach power cables to parking brake cable /
transmission shifting cable bundle with one cable
tie i.

Instr 26-2000 Rev 01 2020-09 Page 6 of 12
4. Put winch in position.
5. Install winch onto vehicle frame with two winch
brackets oand four winch bracket nuts a. Torque
to specification.
TORQUE
Winch Bracket Nuts a:
34 ft-lbs (46 N·m)
6. Attach winch power cables to parking brake cable /
transmission shifting cable bundle with two cable
ties i.
7. Put bundle of cables through hook on seat support
bar.
8. Put red and black cables into battery location. Do
not connect at this time.
REMOTE AND SWITCH INSTALLATION
1. Remove and keep two dash panel fasteners A.

Instr 26-2000 Rev 01 2020-09 Page 7 of 12
2. Remove and keep three dash panel fasteners on
top of panel. Release dash panel from front dash.
3. Remove and keep two fasteners from hood access
panel. Lift off hood access panel, releasing the two
top tabs, and set aside.
4. Cut out blank on dash panel.
5. Install switch ethrough front of dash panel.

Instr 26-2000 Rev 01 2020-09 Page 8 of 12
6. Connect dash harness rto switch.
IMPORTANT
Wires must be connected in order shown.
• Top “Out” – Green wire
• Middle – Red wire
• Bottom “In” – Black wire
7. Drill a 1 in (25 mm) hole in dash panel.
8. Install remote port into drilled hole and mark screw
holes on dash panel. Remove remote port.
9. Drill two holes 5/32 in (4 mm) in dash panel.
10.Install two screws yand two washers uto attach
remote to dashboard. Tighten until fully seated.
11. Connect wire splitter wto switch harness, remote
harness, and vehicle accessory harness.
12.Put remote harness and switch harness down
through vehicle by winch.
13.Connect remote harness tto switch harness r.
Attach to frame with one cable tie i.

Instr 26-2000 Rev 01 2020-09 Page 9 of 12
14.Connect remote harness tto winch harness.
VEHICLE REASSEMBLY
GENERAL
1. Confirm all wiring is correct and there are no
exposed wires or terminals.
2. Tightly wrap all loose wires and secure away from
moving parts and heat sources.
3. Connect positive and negative battery cables as
shown in Owner’s Manual.
WARNING
When BOTH battery cables are disconnected
ALWAYS connect AND tighten red positive (+)
battery cable FIRST. Failure to comply will result in a
high current electrical arc that may result in battery
explosion, if tool touches grounded frame. Death or
serious personal injury may occur.
4. Install seat.
5. Install bumper with five retained bumper bolts.
6. With vehicle key in the ON position, check winch
for proper operation.
OPERATING INSTRUCTIONS
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.

Instr 26-2000 Rev 01 2020-09 Page 10 of 12
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.
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.

Instr 26-2000 Rev 01 2020-09 Page 11 of 12
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

Instr 26-2000 Rev 01 2020-09 Page 12 of 12
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]