Polaris PRO HD 3500 User manual

APPLICATION
Verify accessory fitment at Polaris.com.
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
information.
KIT CONTENTS
This Kit includes:
REF QTY PART DESCRIPTION PART NUMBER
1 1 Winch Mount Bracket 1022610
2 1 Winch Assembly, 3500 HDDS 2206383
3 1 Latch Hook 2411836
4 1 Control Box **
5 1 Rope 2878888
6 1 Wireless Remote Kit 2879316
7 1 Winch Cable, Yellow 6 GA 4013468-750
8 1 Winch Cable, Blue 6 GA 4013469-665
Instr 9927476 Rev 01 2016-11 Page 1 of 12
P/N 2882243
POLARIS®® PRO HD 3500 WINCH KIT

Instr 9927476 Rev 01 2016-11 Page 2 of 12
REF QTY PART DESCRIPTION PART NUMBER
9 1 Winch Power Cable, Black 6 GA 4013470-250
10 1 Winch, Power Cable, Red 6 GA 4013471-250
11 1 Contactor 4015095
12 1 Autostop Fairlead **
13 1 Rubber Stop Magnet **
14 1 Winch Cover 5450852
15* 5Panduit Strap -
16* 4Screw - 1/4 - 20 X 1.50 -
17* 4Screw Torx®Head - M8 X 1.25 X 20 -
18* 2 Screw - M10 X 1.25 X 25 -
19* 4 Screw - Hex Flange - M8 X 1.25 X 25 -
20* 2 Nut - M10 X 1.5 -
1 Winch Guide 9923644
1 Instructions 9927476
Internal Cam Service Kit (includes internal cam for freespool handle to
connect winch to a replaceable handle, purchase handle separately)
2205497
Service Handle (includes freespool handle and screw) 2205265
Items marked (*) are included in Hardware Kit (PN 2205484).
Items marked (**) are included in Kit (PN 2881288).
TOOLS REQUIRED
• Safety Glasses
• 13mm Socket
• 6mm Allen wrench
• 10mm Socket
• #1 Phillips Screwdriver
• T30 Torx®
• 12mm Socket
• T25 Torx®
• Wire Cutter
IMPORTANT
Your POLARIS®PRO HD 3500 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, perform all installation steps correctly in the sequence shown.
ASSEMBLY TIME
Approximately 1 hr.

Instr 9927476 Rev 01 2016-11 Page 3 of 12
INSTALLATION INSTRUCTIONS
PREPARATION
1. Shift vehicle transmission into “PARK”. Turn key to
“OFF” position and remove from vehicle.
2. Remove the seat by pushing and holding the seat
adjuster lever Cdown. Slide the seat forward until
removed from track guides.
3. Disconnect the black negative (-) cable from
battery FIRST, then disconnect red positive (+)
cable from the battery.
WARNING
ALWAYS disconnect black negative (-) cable from
battery FIRST. Failure to comply will result in a high
current electrical arc, and may result in battery
explosion, if tool touches grounded frame. Death or
serious personal injury may occur.
4. Rotate two latches Band open the front storage
bin cover A.

Instr 9927476 Rev 01 2016-11 Page 4 of 12
5. Remove the front storage bin and coverDby
removing two screws Fand six push pin rivets E.
NOTE
Your vehicle’s factory tool kit contains a pliers
specifically designed for the removal of push pin
rivets. See photo below.
6. Remove winch cover Gfrom the vehicle by
removing four screws H. Retain screws for
installing new winch cover supplied in the kit.
NOTE
ACE 570 shown, ACE 900 XC is slightly different.
7. On ACE 900 XC models, remove four screws 1(,
holding the empty winch bracket q, as seen in the
figure below, from the vehicle and remove winch
bracket for use in the next step.
WINCH ASSEMBLY
1. Place fairlead mounting carriage bolts linto
winch bracket as shown. Assemble winch winto
mounting bracket qas shown below using the
supplied screws kand torques to specification.
TORQUE
20 ft. lbs (27.1 Nm)
2. Install the Fairlead dyour kit came with(Autostop
Fairlead shown) onto the winch bracket qusing
supplied locking nuts 2) and torques to
specification.
TORQUE
20 ft. lbs (27.1 Nm)

Instr 9927476 Rev 01 2016-11 Page 5 of 12
WINCH INSTALLATION
NOTE
See the Electric Connections Reference Guide on
the last page of the instruction manual for detailed
photos of each part and their respective connections.
1. Install winch mounting bracket with pre-assembled
winch wand Autostop Fairlead to the chassis
frame using four screws 1( as shown. Torque
screws to specification.
TORQUE
20 ft. lbs (27.1 Nm)
CONTACTOR INSTALLATION
1. Connect red cable aand black cable oto the
corresponding colored posts on contactor.
Similarly, connect yellow cable uand blue
cable ito the colored posts on contactor as
shown.
2. Place the contactor salong with cables installed
on the bracket as shown. Contactor mounting
bracket holes are not threaded. You will need to
thread the holes by running the self-tapping
screws jin from the top as shown.
3. Connect short red aand black ocables to the
vehicle bus bar on same posts as the battery red
and black cables are connected.
4. Feed the yellow uand blue icables down the
right side of the vehicle near the frame tube to the
winch as shown. Hook the cables to the
corresponding colored posts on winch. Slide the
black rubber boots on yellow and blue cables.