Motoalliance MA11806 User manual

Honda Rubicon (Prior to 2004)
Winch Mount Kit
MA11806
23001 Industrial Blvd Rogers, MN 55374
866.527.7637 (toll free) 1 [email protected]
HARDWARE FOR WINCH MOUNT KIT
QTY
DESCRIPTION
2
Mount Plates
2
5/16” x 1” x 1 ¾” U-bolts (42006) U-bolts
2
5/16” x 1-1/8” x 1 ¾” (42012)U-bolts
2
5/16” x 1” Bolt
2
5/16” Flat washer
10
5/16” Nylock Nut
4
7/8” Steel Spacer
4
M6 x 30 Hex Head Bolt
4
¼” Flat washer
MOUNTING INSTRUCTIONS
All directions referring to right and left are when the rider is sitting on the machine. Please Note: The roller hawse, cable clamp,
cable stop and hardware are included with the winch.
1. Remove the front plastic bumper guard. Place the winch mount plate on top of the horizontal bumper support tubes as
shown in picture below. The U-bolts will be placed around the tubes and up through the plate and are secured with nylock
nuts. Tighten fully.
2. Mount the winch to the underside of the winch mount plate using the mount holes in the plate and the provided bolts.
Tighten hardware at this time. Go to instructions for your winch.
-Two –Bolt Winches (SUPERWINCH)
Using the two 5/16” x 1” bolts supplied with kit, mount the winch to the winch mount plate. Be sure that when the winch is
mounted to the ATV, the winch motor is on the RIGHT side of the machine. Go to next instruction.
-Four –Bolt Winches (VIPER, WARN, RAMSEY)
Using the four 5/16” x 3/4” bolts supplied with the winch, mount the winch to the winch mount plate. Be sure that when the
winch is mounted to the ATV, the winch motor is on the LEFT side of the machine. The roller hawse mount plate provided
with the winch will not be used. Go to next instruction.
3. Place the front plastic bumper guard back onto your Honda Rubicon, place the roller hawse mount bracket against the front
plastic bumper guard using the 7/8” steel bushings as spacers. Attach using the 6 x 30mm bolts and flat washers.
4. String the cable through the hole in the hawse mount bracket. Remove one of the long rollers and the two side rollers of the
roller hawse and feed the winch cable through the roller hawse. Reinstall the rollers and be sure rollers move freely.
5. Attach the roller hawse to the hawse mount bracket using the 3/8” x 1” bolts and nylock nuts provided with the winch.
Tighten all hardware.
ELECTRICAL INSTRUCTIONS
1. First determine where to install the contactor (control relay). There is no right or wrong place. We recommend a dry place
away from sharp or moving suspension parts. It can be hard to find a totally dry place on an ATV but just try to find the best
spot. You may mount it in the front, back or under the seat. You may mount it with U-bolts (holes on contactor are metric.) or
bolts. We usually install the contactor in the rear storage compartment if possible because it is dry there. When installing the
contactor in the storage compartment, you should attach all the wires first, before bolting it down. We also offer an optional
side bracket mount. This bracket allows the contactor to hang on the side of square tubing. There is an additional cost
associated with this part and you can call us for details or visit our website.

Honda Rubicon (Prior to 2004)
Winch Mount Kit
MA11806
23001 Industrial Blvd Rogers, MN 55374
866.527.7637 (toll free) 2 [email protected]
2. We used the factory wires installed for the winch. I found the wire taped to the horizontal crossmember above the winch. And I
found contactor side back behind the storage compartment below taillight. Blue = (+)or red on winch and Yellow =(-) or silver
on winch. The factory wires matched Blue and Yellow terminal on the contactor. If you don’t use factory wiring then the
following applies. Take the long set of red/black power wires and attach the red wire to the winch’s red terminal and the black
wire to the silver terminal. Keep the wire away from moving suspension parts. We left wire loose as we went down the upper
frame. When fastening any wire where moisture could cause problems put dielectric tune-up grease (Permatex 22058 from
NAPA) on all connections. Also if you want extra vibration protection, Napa has plastic split loom tube conduct that can also
be installed over the wire after it has been routed through the frame. (Napa #737300, 3/8” split loom) Connecting the wire to
the contactor, you will want the red wire attached to the red nut on the winch motor to go to the blue terminal on the contactor.
(Blue is painted on top of the contactor terminal). The black wire attached to the silver terminal on the winch goes to the yellow
terminal on contactor. If you get this wiring backwards this will not damage anything, the control switch on the handlebars will
just work in reverse.
3. Next, run the power wires from the battery into the compartment or location you have chosen for your contactor. The red wire
goes to the positive terminal on the battery and the red terminal on the contactor. The black wire goes negative terminal on the
battery and the black terminal on contactor. We didn’t attach the red wire until all the rest of the wiring was complete. Caution!
It is easier to reverse the polarity at the battery then you would think and that can cause damage to your voltage regulator,
contactor, and can start fires. The battery is capable of supplying a lot of current even to a short.
4. The last of the wiring is to mount and wire in the control switch on the handle bars. We wrapped a couple wraps of electrical
back tape on the handle bars before we clamped the switch down. Route the control wiring down the vertical wiring harness and
join up with the power cable on left side of cowling. Keep the red wire that hangs out near switched 12 volt wire. Route the
control wire down to the power wire and follow the power wire back to the contactor location. Fasten the green wire to the
green wire on contactor and the black wire to the black wire on the contactor. (The connectors are gender specific and can’t be
reversed.)
5. The red switch control wire is the next item, which often raises some questions. The red control wire hanging out of the control
cable near the switch goes to the switch 12 volts on the ATV. Some ATV’s will have an accessory wire provided and it is
spelled out in the owner’s manual. The wire will be fused for it. The wires can be many different colors. You could also call
an your Honda Service Center & they will give you the location and color wire for winch control switch 12 volts over the phone.
A factory service manual will also have the schematic in it. We found the switch 12 volts by using a 12 volt test light. We
poked a hole though the insulation. With the test light clipped to the frame we turned on the key and lit the light. We turn
turned off the key and light went out. (Switch 12 volts are defined as 12 volts removed with the key off, as opposed to battery
12 volts that has power all the time. You can always find switch 12 volts on the back side of the ignition switch.) You may
obtain a crimp on side tap terminal for taping into insulated wire at an Auto parts store or hardware store. We used the orange
wire on the back side of ignition switch. We tape into switch 12 volts with a side tape crimp on connector. Some
manufacturers provide a connector to plug into under the front access panel. Usually a crimp on spade connector will mate with
it.
6. Lastly, fasten down the contactor with the bolts provided in the winch box. Make sure the 10 MM terminal nuts are tight on the
contactor and wire terminal lugs and not shorting. Double check the green and black control wires on the contactor. They can
mate hard, so make sure they are seated. Then, attach the battery wires to the battery. Your winch is operational. With the
ignition key on, the relay should click when the handle bar control switch is activated. You should test both halves of the switch.
The click is independent of winch powering 12 volts. It will click even if the battery is not wired to the contactor or winch.
Wind in excess winch steel cable by carefully guiding it to the spool. Installation technicians are available to answer questions
that may arise. If further assistance is needed please call our toll-free line at 866-527-7637 and ask to speak with our
technician.

Honda Rubicon (Prior to 2004)
Winch Mount Kit
MA11806
23001 Industrial Blvd Rogers, MN 55374
866.527.7637 (toll free) 3 [email protected]