Kolpin 26-3100 User manual

1
© 2019 Kolpin Outdoors Inc. REV 00
Polaris Sportsman Quick-Mount
2500lb. / 3500lb. Winch Kit
Product Instructions | Part No 26-3100 / 26-3110
1
2
9
7
5
4
Application Polaris Sports an, verify accessory fit ent at Kolpin.co .
Before You Begin Read these instructions and check to be sure all parts and tools are accounted for. Please retain
these installation instructions for future reference and parts ordering infor ation.
Note: If any hardware is missing, do not return to the store. Call us to help, Toll Free 1-877- 56-5746.
8
3
10
6
11
12
15
16
19
20
18 13
14
17
21

2
© 2019 Kolpin Outdoors Inc. REV 00
This Kit includes
• Socket Set, Torx Bit
• Hex Key Set, Metric
• Torque Wrench
• Wire Cutter
Tools Required
• Safety Glasses
• Socket Set, Metric
• Screwdriver, Phillips
Item Qty Part Description
Part Number
26-3100 26-3110
1 1Handlebar Switch 2207175
25Cable Ties, Nylon -
34Hex Flange Screw, Zinc Plated, M8 x 1.25 - 25 LG -
41Mounting Bracket 25-3410
51Winch - Kolpin, 2500lb. / 3500lb. 25-9250R 25-9350R
61Hook, Winch Latch RPR0108
71Winch Cable, (Steel - 2500lb.) / (Synthetic - 3500lb.) 85062 85064
81Winch Connection Cable, Yellow 6 GA (368 ) -
91Winch Connection Cable, Blue 6 GA (267 ) -
10 1Power Connection Cable, Black 6 GA (510 ) -
11 1Power Connection Cable, Red 6 GA (530 ) -
12 1Contactor, Solenoid, 12V 85068
13 1Roller Fairlead 85069
14 1Rubber Winch Stopper (only included on 3500lb.) - 85080
15 4Button Screw, Zinc Plated, M8 x 1.25 - 20 LG -
16 2Socket Head Cap Screw, Zinc Plated, M6 x 1.0 - 10 LG 7517337
17 2Carriage Screw, Zinc Plated, M8 x 1.25 - 20 LG 7518479
18 2Hex Flange Locknut, Zinc Plated, M8 x 1.25 7547317
19 2Routing Clip Cable Tie, Nylon 7081496
20 1SPMN Winch Vehicle Harness -
22 1Instruction Guide (not shown) -
- - Service Free Spool Handle Knob (not included in kit) 85072
21 2Locknut, Zinc Plated, #10-32 7547341
Assembly Time Approxi ately 20 inutes
Sportsman XP Note If you need to install this kit on a Sports an XP 550/850/1000, see the instructions and photos
on page 8. The XP instructions shows the contactor location and wire routing for that configuration, and reasse ble the
contactor and wiring to atch those photos. Then follow the preceding instructions for final installation.
Important Your Kolpin Sports an Quick-Mount Winch Kit is exclusively designed for your vehicle. Please read the
installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For
your safety, and to ensure a satisfactory installation, perfor all installation steps correctly in the sequence shown.

3
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN 450/570 PREPARATION
1. Shift vehicle trans ission into “PARK”. Turn key
to “OFF” position and re ove fro vehicle.
2. Detach the rubber latch on both sides to open
front rack as shown. (See illustration 1-1).
3. Open the front rack and re ove rubber seal as
shown. Retain the seal for reinstallation. (See
illustration 1-2).
4. Re ove four screws holding front cover in place
as shown. Retain the screws for reinstallation.
(See illustration 1-3).
5. Lift the front cover upwards slowly to disengage
the tabs on cover fro the slots as shown. (See
illustration 1-4).
6. Disconnect black (negative) and red (positive)
cables fro battery.
7. Disconnect the black (negative) and red (positive)
cables fro the busbar as shown. (See
illustration 1-5).
8. Re ove the accessory front brush guard fro
vehicle (if equipped).
Ill. 1-1
Ill. 1-2
Rubber
Latch
Ill. 1-3
Rubber
seal
Front
Rack
Screws
Front
Cover
Ill. 1-4
Front
Cover
Slots
WARNING
ALWAYS disconnect black negative (-) cable
fro battery FIRST. Failure to do so will result
in high current electrical arc, and ay result in
battery explosion if tool touches grounded
fra e. Death or serious injury ay occur.
!
!
Ill. 1-5
Black
Cable
Red
Cable
Busbar

4
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN 450/570 PREPARATION
(continued)
9. Re ove lower front bu per cover fro vehicle by
re oving four bolts as shown. Retain bolts for use
during reinstallation. (See illustration 1-6).
10. Re ove winch cover fro the lower front bu per
cover. If you plan to use a plow, re ove winch
cover fro the lower front bu per cover and do
not reinstall. If you do not plan to use a plow on
your vehicle, cut out the center section as shown
and reinstall winch cover on the lower front
bu per cover if you desire, but it is not required.
(See illustrations 1-7 and 1-8).
NOTE: Before installing the winch kit, add or replace the proper
fluid to your front gearcase as required per your vehicles service
manual as this process will be difficult to do after the winch is installed.
SPORTSMAN 450/570 WINCH INSTALLATION
NOTE: See the Electrical Connections Reference Guide section
of the instruction manual for detailed photos of each part and their
respective connections.
11. Check and confir wire routing and connections are as shown and ake
necessary adjust ent before oving to next installation steps. (See
illustration 1-9).
12. On vehicle, locate white contactor connector as shown, clip plastic cable
tie, re ove the cap. (See illustration 1-10).
Ill. 1-6
Ill. 1-7
Front
Lower
Bu per
Cover
Ill. 1-8
Winch
Cover
OEM
bolts
Ill. 1-9
Red
Cable
Black
Cable
Tri ed
Winch
Cover
Use this routing clip. Close two
wires and tri excess tie.
This cable tie will
not be used and can
be re oved fro
this clip.
Ill. 1-10
Cable
Tie
Connector
Cap

5
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN 450/570 WINCH INSTALLATION (continued)
13. Locate the red and black wires on winch asse bly. If they are
secured to blue cable with a plastic tie, cut the tie to allow the
wires to be routed properly. (See illustration 1-11).
14. Re ove the accessory front brush guard fro vehicle (if
equipped).
15. Install winch asse bly onto the radiator ount with the
four M8 hex flange screws (ite #3). Check that all
wires are free to ove and not pinched between the
vehicle chassis and the winch asse bly. Access is
easier by inserting the black and red power cables first
into window above front gearcase as shown, then
position winch otor side into bu per fra e first
followed by lifting clutch free spool handle end last.
(See illustrations 1-12, 1-13 and 1-14).
16. Tighten the four M8 screws (ite #3) to torque
specification.
Ill. 1-11
Ill. 1-12
Ill. 1-13
Bu per
Fra e
Clutch
Free
Spool
Winch
Motor
side
Re ove
packaging
tie
Front
Gearcase
Black
Cable
Red
Cable
Ill. 1-14
3
8MM FASTENER TORQUE
17 ft. lbs. (23 N )

6
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN 450/570 WINCH
INSTALLATION (continued)
17. Route red positive (ite #11) and black
negative (ite #10) power connection
cables directly underneath the radiator
then up behind it to reach the three
ter inal bus bar as shown. Using two of
the plastic cable ties (ite #2), loosely
secure the red and black power cables to
the fra e and existing wiring. (See
illustration 1-15).
Note, do not connect
the winch cables to the busbar at this
time.
18. For 2015 & Newer Vehicles: Locate the
white connector on the contactor and
connect it to the corresponding connector
on the vehicle harness as shown. (See
illustration 1-16).
19. For 2014 & Older Vehicles: Route the
supplied SPMN winch vehicle harness
(ite #20) fro the head light pod down
to winch, using sa e path behind radiator
as the black and red winch power cables.
Connect the white harness connector to
the winch contactor connector. Route the
red end (12V accessory power) of
harness to busbar area and connect to
orange wire on vehicle ain harness as
shown. Secure winch harness to vehicle
using cable ties (ite #2). (See illustration
1-17).
20. Now connect the vehicle battery red and
black wires to the busbar ter inals and fasten using existing nut.
Then connect the winch power cables, red and black, (ite s #11
and #10) to the busbar ter inal and fasten using supplied nut
(ite #21) as shown. (See illustration 1-18).
Ill. 1-15
Ill. 1-16
Vehicle
Connector
Contactor
Connector
Overhead view
Ill. 1-18
11
10
2
2
11
10
21
21
Ill. 1-17
Orange
Wire

7
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN 450/570 HANDLEBAR SWITCH
INSTALLATION
21. Install the handlebar switch (ite #1) using the
supplied screws onto the handlebar as shown.
Torque screws to the specification listed, being
careful not to overtighten. (See illustration 1-19).
22.
For 2015 & Newer Vehicles: Re ove cap fro
vehicle switch connector. Then connect handlebar
switch connector to the vehicle ain wire harness
as shown. (See illustration 1-20).
23. For 2014 & Older Vehicles: Route the supplied
SPMN winch vehicle harness (ite #20) up
through the headlight pod towards left-hand grip
area. Use cable tie (ite #2) to secure switch
connector end to handlebar as shown. Then
connect handlebar switch connector to the winch
harness as shown (See illustration 1-20).
SPORTSMAN 450/570 FINAL INSPECTION
24. Confir that all wiring is correct.
25. Confir that there are no exposed wires or ter inals.
26. All loose wires need to be wrapped tight, and secured away fro
oving parts and heat sources.
SPORTSMAN 450/570 REINSTALLATION
27. Reinstall the lower front bu per cover. If you plan to use a plow, do
not reinstall winch cover. (See illustration 1-21).
28. If you do not plan to use a plow, reinstall winch cover. (See
illustration 1-22).
29. Reinstall accessory brush guard (if equipped).
30. Reconnect battery red (positive) and black (negative) cables to
battery ter inals at this ti e.
31. Reinstall the front cover (under front rack) using retained screws.
32. Close front rack and secure in place with rubber latches.
33. With vehicle key in the ON position, check winch for proper
operation.
1
Ill. 1-19
Supplied
Screws
SWITCH SCREW FASTENER
TORQUE
2 ft. lbs. (2.7 N )
Ill. 1-20
Vehicle
Switch
Connector
Ill. 1-21
Ill. 1-22
Front
Bu per
Cover
Front
Bu per
Cover
Winch Cover

8
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP 550/850/1000
PREPARATION
1. Shift vehicle trans ission into “PARK”. Turn key
to “OFF” position and re ove fro vehicle.
2. Detach the rubber latch on both sides to open
front rack.
3. Rotate/open two latches and re ove storage tray
fro vehicle as shown. (See illustration 1-24).
4. Disconnect black (negative) and red (positive)
cables fro battery as shown. (See illustration
1-25).
5. Re ove the accessory front brush guard fro
vehicle (if equipped).
6. Re ove the lower front bu per cover by
re oving four bolts. Retain bolts for use during
reinstallation as shown. (See illustration 1-26).
7. Re ove the winch cover fro the front lower
bu per cover by re oving two push pin rivets.
The winch cover and push pin rivets will not be
needed while the winch is installed on the vehicle
as shown. (See illustration 1-27).
Note, your
vehicle’s factory tool kit contains a pliers
specifically designed for the removal of push
pin rivets.
Ill. 1-24
Black
Cable
Storage
Tray
Screws
Red
Cable
WARNING
ALWAYS disconnect black negative (-) cable
fro battery FIRST. Failure to do so will result
in high current electrical arc, and ay result in
battery explosion if tool touches grounded
fra e. Death or serious injury ay occur.
!
!
Winch
Cover
Plastic
Push
Rivet
Bu per
Cover
Ill. 1-25
Ill. 1-26
Ill. 1-27
Bu per
Cover

9
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP 550/850/1000 PREPARATION
(continued)
NOTE: Before installing the winch kit, add or
replace the proper fluid to your front gearcase as
required per your vehicles service manual as this
process will be difficult to do after the winch is
installed.
SPORTSMAN XP 550/850/1000 WINCH
INSTALLATION
NOTE: See the Electrical Connections
Reference Guide section of the instruction manual for
detailed photos of each part and their respective
connections.
8. Locate the red and black wires on winch
asse bly. If they are secured to blue cable with
a plastic tie, cut the tie to allow the wires to be
routed properly. (See illustration 1-11).
9. The 26-3100 / 26-3110 winch asse bly contains
the sa e parts to work on Sports an 450/570
and Sports an XP 550/850/1000. The winch
pre-asse bly will need the contactor to be
relocated to fit on Sports an XP 550/850/1000
vehicles. First loosen the red (ite #11), black
(ite #10), blue (ite #9) and yellow (ite #8)
connection cables fro winch (ite #5) and
contactor (ite #12). Then loosen and re ove
the M6 socket head cap screws (ite #16) that
secure contactor to ounting
bracket (ite #4) as shown. (See
illustration 1-28).
10. Relocate the contactor to the back
tab of the ounting bracket as
shown. Secure the contactor to
bracket using the two M6 socket
head cap screws. (See
illustrations 1-29 and 1-30).
11. Torque to M6 specification.
Ill. 1-28
Screws
re oved
Contactor
ready for
relocation
Ill. 1-29
Ill. 1-30
16
12
Relocated
Contactor
to back tab
6MM FASTENER TORQUE
7 ft. lbs. (9.5 N )

10
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP
550/850/1000 WINCH
INSTALLATION
(continued)
12. Check and confir wire
routing and connections
are as shown and ake
necessary adjust ents
before oving to next
installation steps. (See
illustrations 1-31 and
1-32).
13. Install winch asse bly
onto the radiator ount
with the four M8 hex
flange screws (ite #3).
Check that all wires are free to ove and not
pinched between the vehicle chassis and the winch
asse bly. Access is easier by inserting the black
and red power cables first into window above front
gearcase as, then position winch asse bly into
vehicle chassis as shown. (See illustrations 1-33
and 1-34).
14. Tighten the four M8 screws (ite #3) to torque
specification.
Ill. 1-31
Red
Cable
Black
Cable
Use this routing clip. Close two
wires and tri excess tie.
This cable tie
will not be
used and can
be re oved
fro this clip.
Ill. 1-33
Ill. 1-32
8MM FASTENER TORQUE
17 ft. lbs. (23 N )
3
Ill. 1-34
3

11
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP 550/850/1000 WINCH
INSTALLATION (continued)
15. Route red positive (ite #11) and black negative
(ite #10) power connection cables to the battery
as shown. Attach cables to chassis fra e at
required locations using cable ties. (See
illustrations 1-35, 1-36 and 1-37). Note, do not
connect the winch cables to the battery at this
time.
16. For 2015 & Newer Vehicles: On vehicle, locate
white contactor connector on fra e tube behind
front left tire as shown. Re ove cap fro ain
harness connector and connect to the white
contactor winch
connection. (See
illustration 1-38).
Ill. 1-38
Cable
Tie
Connector
Cap
Ill. 1-35
Ill. 1-37
Cable
Tie
11
10
11
10
Cable
Tie
Ill. 1-36

12
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP 550/850/1000 WINCH
INSTALLATION (continued)
17.
For 2014 & Older Vehicles: Route the
supplied SPMN winch vehicle harness (ite
#20) fro the head light pod down to winch,
using sa e path along radiator as the black
winch power cables. Connect the white harness
connector to the winch contactor connector.
Route the red end (12V accessory power) of
harness to busbar area and connect to orange
wire on vehicle ain harness as shown. Secure
winch harness to vehicle using cable ties (ite
#2). (See illustration 1-39).
SPORTSMAN XP 550/850/1000 HANDLEBAR
SWITCH INSTALLATION
18. Install the handlebar switch (ite #1) using the
supplied screws onto the handlebar as shown.
Torque screws to the specification listed, being
careful not to overtighten. (See illustration 1-40).
19.
For 2015 & Newer Vehicles: Re ove cap fro
vehicle switch connector. Then connect handlebar
switch connector to the vehicle ain wire harness
as shown. (See illustration 1-41).
20.
For 2014 & Older Vehicles: Route the supplied
SPMN winch vehicle harness (ite #20) up
through the headlight pod towards left-hand grip
area. Use cable tie (ite #2) to secure switch
connector end to handlebar as shown. Then
connect handlebar switch connector to the winch
harness as shown (See illustration 1-41).
SPORTSMAN XP 550/850/1000 FINAL
INSPECTION
21. Confir that all wiring is correct.
22. Confir that there are no exposed wires or ter inals.
23. All loose wires need to be wrapped tight, and secured away fro oving parts
and heat sources.
Ill. 1-39
Orange
Wire
1
Ill. 1-40
Supplied
Screws
SWITCH SCREW FASTENER
TORQUE
2 ft. lbs. (2.7 N )
Ill. 1-41
Vehicle
Switch
Connector

13
© 2019 Kolpin Outdoors Inc. REV 00
SPORTSMAN XP 550/850/1000 REINSTALLATION
24. Reinstall the front bu per cover on vehicle using
retained screws.
25. Reinstall accessory brush guard (if equipped).
26. Reinstall red and black cables to battery ter inals
along with winch power cables (ite s #10 and #11)
using screws as shown. (See illustration 1-42).
27. Reinstall storage tray on the vehicle.
28. Close the front rack and secure in place with rubber
latches.
29. With vehicle key in the ON position, check winch for
proper operation.
HANDLEBAR SWITCH OPERATION
When properly installed, the handlebar switch allows you to
operate the winch while seated on the vehicle. Proper switch
operation is shown. (See illustration 1-43).
Ill. 1-42
11
10
Battery
Screws
For additional assistance, please contact Kolpin custo er service depart ent at
[phone] or [phone] or e ail custo [email protected]
Five Year Mechanical Limited Warranty and Three Year Electrical Limited Warranty
For the period of five (5) years fro the purchase date, Kolpin will replace for the original purchaser, free of charge, any echanical
part or echanical parts found upon exa ination by Kolpin to be defective in aterial, work anship, or both. For the period of three
(3) years fro the purchase date, Kolpin will replace for the original purchaser, free of charge, any electrical part or electrical parts
found upon exa ination by Kolpin to be defective in aterial, work anship, or both.
All transportation costs incurred sub itting product to Kolpin for warranty consideration ust be borne by the purchaser. If Kolpin
deter ines that the product ust be returned to the factory for credit, please call 1-877-956-5746 for a Return Merchandise
Authorization (RMA) nu ber and shipping instructions.
This warranty does not apply to parts that have been da aged by accident, alteration, abuse, i proper aintenance, nor al wear, or
other causes beyond the anufacturer’s control. In order to protect you and your ATV, certain parts of the winch/plow syste and/or
hardware are designed to fail when the equip ent is over-stressed. Parts that are lost due to loosening and i proper aintenance
are not covered under warranty. This warranty does not cover re oval or reinstallation labor fees of the winch/plow syste and
related co ponents.
Peripheral products such as engines, electric otors, and actuators ay carry an original anufacturer’s warranty. Most hardware is
general in nature and is easily obtained locally. Be sure to replace with ini u etric class 8.8 specification.
Kolpin Outdoors, Inc.
www.kolpin.com
Ill. 1-43

14
© 2019 Kolpin Outdoors Inc. REV 00
TROUBLESHOOTING
If your winch is not functioning properly, below is a short guide that can help you diagnose and correct the proble .
NOTE
For further technical support, contact our help line at
1-877-956-5746.
Symptom Possible Causes Recommended Solution
Winch will not
operate
Contactor not receiving power Turn vehicle key on.
Connections between co ponents not in
proper order
Check connections. Connect wired handlebar switch
connection fro vehicle ain wire harness directly to
contactor to ake sure a direct connection will operate the
winch. If connections are not in the order shown in the pictures
in the last page, the whole syste ay 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 co ing out of the ain
harness by the steering post.
Contactor alfunctioning
Tap contactor to loosen contacts. Apply 12 volts to coil
ter inals directly. A clicking indicates proper activation.
Defective switch asse bly Replace switch asse bly.
Defective otor
Check for voltage at ar ature port with switch pressed. If
voltage is present, replace winch asse bly.
Nested and bounded cable within winch
asse bly
Move free spool knob to the “free spool” position. Manually pull
cable out of winch until end is et and then re-spool cable
back into winch.
Water has entered otor
Allow to drain and dry. Run in short bursts without load until
co pletely dry.
Contactor powered, but not winch
If you can hear a clicking sound when you press the winch
control but the winch does not ake 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 proble persists, a qualified technician needs to
check and repair.
Winch
operates too
slowly
Insufficient current or voltage
The battery is weak, recharge. Run winch with vehicle otor
running (battery should have a strong charge).
Loose or corroded battery cable
connections
Clean, tighten, or replace.
Winch
overheating
Winch running ti e 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 asse bly Replace switch asse bly.
Defective brake asse bly Replace winch asse bly.
Winch akes
noise but rope
does not ove
Winch i properly loaded Check that the winch is clear and the rope 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.

15
© 2019 Kolpin Outdoors Inc. REV 00
ELECTRICAL CONNECTION REFERENCE GUIDE
Winch with Roller Fairlead and Handlebar Switch
Winch with SPMN Winch Vehicle Harness, Roller Fairlead and Handlebar Switch
1
9
5
8
10
11
12
20
1
9
5
8
11
12
10
To vehicle ain
wire harness
To vehicle ain
wire harness
Connect
harnesses
together
Connect
harnesses
together
To vehicle
accessory power
(orange) wire