Kolpin Outdoors POLARIS SPORTSMAN Installation and operating instructions

QUICK-MOUNT WINCH KIT
Assembly / Owner’s Manual
APPLICATION: Polaris Sportsman®
Verify accessory fitment at Kolpin.com
Instr 26-3200; 26-3210 Rev 01 2020-11 Page 1 of 17
P/N 26-3200; 26-3210
POLARIS SPORTSMAN®QUICK-MOUNT
2500 LB / 3500 LB WINCH KIT

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 2 of 17
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.
ASSEMBLY TIME
Approximately 30 minutes
SAFETY INFORMATION
Please read and understand all assembly instructions, notices, and warnings before assembling and operating
your Kolpin winch.
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
• Pliers, Push Pin Rivet
• Socket Set, Metric
• Socket Set, Torx®Bit
• Torque Wrench
• Wrench Set, Metric

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 3 of 17
KIT CONTENTS
2500 LB WINCH P/N 26-3200; 3500 LB WINCH P/N 26-3210
NOTICE
2500 lb Winch shown, 3500 lb similar.
REF QTY PART DESCRIPTION PART NUMBER
1 1 Winch Assembly – Polaris®2500 lb
Winch Assembly – Polaris®3500 lb
n/a
2 1 Wire Harness n/a
3.1 1 Switch 85096
3.2 1 Switch Housing, Front 85096
3.3 1 Switch Housing, Rear 85096
3.4 1 Screw – Torx®Pan Head, 10 x 5/8 in, HI/LO 85096
4 5 Cable Tie 7080492
5 2 Nut – Lock, 10-32 7547341
6 4 Screw – Hex Flange, M8 x 1.25 x 25 mm 7519739

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 4 of 17
2500 LB WINCH P/N 26-3200; 3500 LB WINCH P/N 26-3210 WINCH DETAIL
NOTICE
2500 lb Winch shown, 3500 lb similar.
REF QTY PART DESCRIPTION PART NUMBER
1.1 2 Nut – Hex Flange, M8 x 1.25 mm 7547317
1.2 1 Roller Hawse 85069
1.3 1 Winch Bracket 25-3410
1.4 4 Screw – Torx®Truss Head, M8 x 1.25 x 20 mm 7519260
1.5 1 Cable – Red, 6 GA n/a
1.6 1 Cable – Black, 6 GA n/a
1.7 2 Screw – Socket Head, M6 x 1.0 x 10.0 mm 7517337
1.8 1 Contactor 85068
1.9 1 Cable – Blue, 6 GA n/a
1.10 1 Cable – Yellow, 6 GA n/a
1.11 1 Winch, 2500 lb
Winch, 3500 lb
25-9250R
25-9350R
1.12 2 Routing Clip 7081496
1.13 2 Screw – Carriage Bolt, M8 x 1.25 x 20 mm 7518479
1.14 1 Cable – Steel, 3/16 in
Rope – Synthetic, 3/16 in
85062
85065

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 5 of 17
REF QTY PART DESCRIPTION PART NUMBER
1.15 1 Roller Hawse Hook RPR0108
1.16 1 Strap, Kolpin®Orange 85071
1 Winch Stop, Rubber – not shown (26–3210 only) 85080
INSTALLATION INSTRUCTIONS
Vehicle Preparation, Accessory Installation, and
Vehicle Reassembly instructions are provided for:
• 2021 Sportsman 450/570 models
• 2014–2020 Sportsman 450/570 models
• 2013–2021 Sportsman 850/1000 models
Proceed with installation procedures that best fit your
model.
VEHICLE PREPARATION
GENERAL
1. Park vehicle on a flat surface.
2. Push engine stop switch to OFF position.
3. Turn key to OFF position and remove key.
4. Remove accessory front brush guard from vehicle,
if equipped. See Kit Instructions for procedure.
5. Release rubber latch on both sides and open front
rack.
2021 SPORTSMAN 450/570 MODELS
1. Remove and keep nut from black (negative)
battery cable and disconnect negative battery
cable. Move boot off red (positive) battery cable.
Remove and keep nut from red (positive) battery
cable and disconnect positive battery cable.
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 personal injury may occur.
2. Remove and keep four bolts from lower front
bumper cover. Remove lower front bumper cover.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 6 of 17
3. Remove and discard two push pin rivets from
panel on front bumper cover. Remove and discard
panel.
2014–2020 SPORTSMAN 450/570 MODELS
1. Remove and keep rubber seal C.
2. Remove and keep four screws Dfrom front cover
E.
3. Lift front cover upwards slowly to disengage tabs
on cover from slots F.
4. Remove and keep nut from black (negative)
battery cable and disconnect negative battery
cable. Move boot off red (positive) battery cable.
Remove and keep nut from red (positive) battery
cable and disconnect positive battery cable.
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 personal injury may occur.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 7 of 17
5. Remove and keep four lower front bumper cover
bolts K.
6. Remove winch cover from lower front bumper
cover.
TIP
If you plan to use a plow, do not reinstall lower front
bumper cover. If you do not plan to use a plow, you
may either cut out center section as shown and
reinstall winch cover to lower front bumper cover, or
choose to not reinstall.
NOTICE
Before installing winch kit, add or replace proper fluid
to your vehicle's front gear case as required in the
service manual. This process will be difficult to do
after winch is installed.
2013–2021 SPORTSMAN 850/1000 MODELS
1. Turn two latches and lift out storage bin.
2. Fold up ends of battery cover to access battery
bolts.
3. Disconnect black (negative) and red (positive)
cables from battery.
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 personal injury may occur.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 8 of 17
4. Remove and keep four bolts from lower front
bumper cover.
5. Remove and discard two push pin rivets from
winch cover. Remove and discard winch cover.
NOTICE
Before installing winch kit, add or replace proper fluid
to your vehicle's front gear case as required in the
service manual. This process will be difficult to do
after winch is installed.
ACCESSORY INSTALLATION
WINCH INSTALLATION
2021 SPORTSMAN 450/570 MODELS
1. Make sure wire routing and connections are as
shown and make necessary adjustments.
2. Put red and black wires through the opening
where the winch will go. Move winch onto radiator
mount.
IMPORTANT
Check all wires are free to move, not pinched
between vehicle chassis and winch assembly.
3. Install two screws yon each side to attach winch.
Torque to specification.
NOTICE
On models with strut front suspension, use front set
of holes for mounting winch.
TORQUE
Winch Mounting Screws y:
17 ft-lbs (23 N·m)

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 9 of 17
4. Put red and black winch harness up vehicle frame
behind radiator and through opening in body panel
on negative side of battery.
5. Attach red and black winch harness to main
vehicle frame about halfway between winch and
body panel with cable tie.
6. Locate white connector on contactor. Connect it to
the corresponding connector on vehicle harness.
WINCH INSTALLATION
2014–2020 SPORTSMAN 450/570 MODELS
1. Loosen red, black, blue, and yellow connection
cables from winch and contactor.
2. Remove and keep two screws 1.7 from the
contactor 1.8.
3. Move contactor 1.8 to side tab of mounting
bracket. Attach with two screws 1.7. Torque to
specification.
TORQUE
Contactor Screw 1.7:
7 ft-lbs (9.5 N·m)
4. Make sure wire routing and connections are as
shown and make necessary adjustments.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 10 of 17
5. Locate white contactor connector Mon vehicle.
Cut cable tie and remove cap.
6. Put red and black wires through the opening
where the winch will go. Move winch onto radiator
mount.
IMPORTANT
Check all wires are free to move, not pinched
between vehicle chassis and winch assembly.
7. Install two screws yon each side to attach winch.
Torque to specification.
TORQUE
Winch Mounting Screws y:
17 ft-lbs (23 N·m)
8. Put red (positive) and black (negative) power
cables directly underneath the radiator, then up
behind it to reach the three terminal bus bar.
IMPORTANT
Do not connect winch cables to busbar at this time.
9. Using two cable ties r, loosely secure red and
black power cables to frame and existing wiring.
10.For 2015-2020 models: Locate white connector
on contactor. Connect it to the corresponding
connector on vehicle harness.
11. For 2014 and Older models: Put SPMN winch
harness wfrom head light pod down to winch,
using same path behind radiator as the power
cables. Connect white harness connector to winch
contactor connector. Put red end of harness to
busbar area and connect to orange wire on vehicle
main harness. Secure winch harness to vehicle
with cable ties.
12.Connect red and black winch power cables to the
busbar terminal and fasten using two nuts t.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 11 of 17
WINCH INSTALLATION
2013–2021 SPORTSMAN 850/1000 MODELS
1. Make sure wire routing and connections are as
shown and make necessary adjustments.
2. Put red and black wires through the opening
where the winch will go. Move winch onto radiator
mount.
IMPORTANT
Check all wires are free to move, not pinched
between vehicle chassis and winch assembly.
3. Install two screws yon each side to attach winch.
Torque to specification.
TORQUE
Winch Mounting Screws y:
17 ft-lbs (23 N·m)
4. Put red (positive) and black (negative) power
cables to battery area.
IMPORTANT
Do not connect winch cables to battery at this time.
5. Attach cables to chassis frame with cable tie r.
6. For 2015 and Newer Vehicles: Locate white
contactor connector on frame tube behind front left
tire. Remove cap from main harness connector
and connect to white contactor winch connection.
7. For 2014 and Older Vehicles: Put SPMN winch
harness wfrom head light pod down to winch,
using same path behind radiator as the power
cables. Connect white harness connector to winch
contactor connector. Put red end of harness to
busbar area and connect to orange wire on vehicle
main harness.
HANDLEBAR SWITCH INSTALLATION
ALL MODELS
1. Install handlebar switch front 3.2 and switch rear
3.3 to handlebar with two screws 3.4 Torque to
specification.
NOTICE
Handlebar switch fits in between the main controls
and the brake mount.
TORQUE
Handlebar Screw 3.4:
24 in-lbs (2.7 N·m)

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 12 of 17
2. Connect handlebar switch connector to vehicle
main wire harness.
NOTICE
Vehicle main wire harness connector is either
attached to the handlebars where it can be seen or
will be inside the headlight pod where it cannot be
seen. The cap on the vehicle connector must be
removed.
VEHICLE REASSEMBLY
GENERAL
1. Make sure there are no exposed wires or
terminals. Tightly bind all loose wires and attach
away from moving parts and heat sources.
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.
2021 SPORTSMAN 450/570 MODELS
1. Connect all red (positive) wires to the positive
battery terminal. Connect all black (negative) wires
to the negative battery terminal.
TIP
Put the winch wire through the opening in the
electrical boot that covers the main vehicle power
wire.
TORQUE
Battery Bolt:
60 in-lbs (6 N·m)
2. Put front bumper cover onto vehicle and identify
area to be trimmed on both sides of bumper cover.
3. Cut along marked lines.
4. Install front bumper cover with four fasteners.
Tighten until fully seated.
5. Close front rack and attach two rubber latches.
6. Install accessory front brush guard, if equipped.
See Kit Instructions for procedure.
7. With vehicle key in ON position, test winch for
proper operation.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 13 of 17
2014–2020 SPORTSMAN 450/570 MODELS
1. If you do not plan to use a plow, reinstall winch
cover.
2. Install front bumper cover with four fasteners.
Tighten until fully seated.
3. Connect all red positive wires to the positive
battery terminal. Connect all black negative wires
to the negative battery terminal. Torque to
specification.
TORQUE
Battery Bolt:
60 in-lbs (6 N·m)
4. Lower front cover down slowly to engage tabs on
cover into slots F.
5. Install four screws Dto front cover. Tighten until
fully seated.
6. Install rubber seal.
7. Close front rack and attach two rubber latches.
8. Install accessory front brush guard, if equipped.
See Kit Instructions for procedure.
9. With vehicle key in ON position, test winch for
proper operation.

Instr 26-3200; 26-3210 Rev 01 2020-11 Page 14 of 17
2013–2021 SPORTSMAN 850/1000 MODELS
1. Connect all red positive wires to the positive
battery terminal. Connect all black negative wires
to the negative battery terminal. Torque to
specification.
TORQUE
Battery Bolt:
60 in-lbs (6 N·m)
2. Install front storage bin and attach two fasteners.
3. Install front bumper cover with four fasteners.
Tighten until fully seated.
4. Close front rack and attach two rubber latches.
5. Install accessory front brush guard, if equipped.
See Kit Instructions for procedure.
6. With vehicle key in ON position, test winch for
proper operation.
OPERATION
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 26-3200; 26-3210 Rev 01 2020-11 Page 15 of 17
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 26-3200; 26-3210 Rev 01 2020-11 Page 16 of 17
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 26-3200; 26-3210 Rev 01 2020-11 Page 17 of 17
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]