Polaris 3500 User manual

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Before you begin, read these instructions twice and check to be sure all parts and tools are accounted for. Please
retain these installation instructions for future reference and parts ordering information.
P/N 2879461; 2879462
WINCH 3500 AND 4500 KIT
Application
RZR XP 1000
3500 Winch Kit Contents:
Ref Qty Part Description Part Number
1 1 Winch-Polaris, 3.5 2204688
2 1 Hook-Latch, Winch 2411836
3 1 Roller-Fairlead, Winch 25/3500 2411848
4 1 Cable-Winch, Steel, 3/16” 2878890
5 1 Contactor-Winch 4013465
6 1 Remote-Switch, Winch 4013466
7 1 Socket-Winch 4014228
8 1 Cable-Winch, Yellow 6 GA, 480mm 4013468-480
9 1 Cable-Winch, Blue 6 GA, 400mm 4013469-400
10 1 Power Cable, Winch, Black 6 GA, 375mm 4013470-375
11 1 Power Cable, Winch, Red 6 GA, 375mm 4013471-375
12 1 Power Bracket, Winch, Red RZN 5257962
13 1 Fairlead Bracket Mount, RZN 5257963
14 1 Cable-Assembly, Battery to Terminal Block 4014577
15*2 Screw-M5x0.8X208.8TXPH ZOD 7518980
16*2 Nut-M5X0.8X8.8 HX/FL NYLOC 7547427
17*4 Screw-HXFL-M6X35 ZOD HILO 7519330
18*6 Nut-M10X1.5 HFN NYLOC-ZOD 7547423
19*4 Nut-M12X1.75, FLG, NYLOC-OLIVE D 7547441
1
7
10 11
8
5
9
13
4
12
14
6
3
2

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4500 Winch Kit Contents:
Ref Qty Part Description Part Number
1 1 Winch-Polaris, 4.5, BTM SPL 2204855
2 1 Hook-Latch, Winch 2411836
3 1 Fairlead, HAWSE, MACH, WIDE 2879148
4 1 Stop-Magnet, Bumper, Rubber 5414619
5 1 Rope Kit, Winch, 45, UHMW 2879187
6 1 Contactor-Winch 4013465
7 1 Remote-Switch, Winch 4013466
8 1 Socket-Winch 4014228
9 1 Cable-Winch, Yellow 6 GA, 480mm 4013468-480
10 1 Cable-Winch, Blue 6 GA, 400mm 4013469-400
11 1 Power Cable, Winch, Winch, Black 6 GA, 375mm 4013470-375
12 1 Power Cable, Winch, Winch, Red 6 GA, 375mm 4013471-375
13 1 Power Bracket, Winch, Red RZN 5257962
14 1 Mount-Fairlead, 4.5, RZN 5258106
15 1 Cable-Assembly, Battery to Terminal Block 4014577
16*2 Screw-M5x0.8X208.8TXPH ZOD 7518980
Ref Qty Part Description Part Number
20*6 Screw-RHCAR-MX10X1.5X25 8.8 ZOD 7519372
21*4 Screw-M12x1.75X25 8.8 HXFL ZOD 7519072
22*4 Screw-HXFL-M8X1.25X20 8.8 ZOD P3 7519133
23*2 Screw-SH-M10X1.5X25 8.8 ZPB D513 7517358
1 Instructions 9924528
1 Manual-Winch Guide 9923644
0 Service Kit Handle, HD Winch 2205265
Item marked (*) are included in Hardware Kit PN 2205119.
3
11
2
14
9
12
7
8
15
10
13
6
5
1
4

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Ref Qty Part Description Part Number
17*2 Nut-M5X0.8X8.8 HX/FL NYLOC 7547427
18*4 Screw-HXFL-M6X35 ZOD HILO 7519330
19*6 Nut-M10X1.5 HFN NYLOC–ZOD 7547423
20*4 Nut-M12X1.75, FLG, NYLOC–OLIVE D 7547441
21*6 Screw-RHCAR-MX10X1.5X25 8.8 ZOD 7519372
22*4 Screw-M12x1.75X25 8.8 HXFL ZOD 7519072
23*4 Screw-HXFL-M8X1.25X20 8.8 ZOD P3 7519133
24*2 Screw-SH-M10X1.5X25 8.8 ZPB D513 7517358
1 Instructions 9924528
1 Manual-Winch Guide 9923644
Internal Cam Service Kit (Includes internal cam 2205497
for freespool handle to connect winch to a
replaceable handle, purchase handle separately)
Service Handle (Includes freespool handle and screw) 2205265
Item marked (*) are included in Hardware Kit PN 2205119.
Tools Required:
Standard and Metric Socket Set Standard and Metric Wrench Set
Drill and Bit Set Torque Drivers
Philips Screwdriver 1 1/6” Hole Saw or Drill
IMPORTANT: Your Polaris RZR XP 1000 WINCH 3500 and 4500 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. Before you begin, thoroughly review
the instructions. Ensure you have all the required tools and the skills necessary to complete this
installation.
APPROXIMATE ASSEMBLY TIME: 45 minutes

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INSTALLATION INSTRUCTIONS
1. Place the vehicle in “PARK” and turn the key to
“OFF” position. Remove the key from the vehicle.
Remove the driver seat. Disconnect the black
negative and the red positive battery cable from the
battery. Figure 1.
2. Remove the hood from the vehicle by twisting the
two knobs and pulling up. Figure 2.
3. Remove the shift lever cap by using a at
screwdriver to remove the cap of the shift handle.
Remove the handle screw with a T25 Torx bit
retaining it for reuse and pull up to remove the
handle from the shift lever weldment. Figure 3.
Figure 1
Battery Cables
Under Seat
Figure 2
Figure 3
Knob
Cap
Shift
Housing
Pull
Pull

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4. After removing shift lever cap and shift handle, take
off the center console by removing the two screws
(PN 7519650) and the four tuff lock rivets
(PN 7661855). Figure 4.
5. Route the cable (PN 4014577) having red and black
wires from bus bar to the battery.
Clip the harness to specied locations.Figure 5.
NOTE: The red and black wires are supplied with
the kit.
IMPORTANT: Do not connect the wire to the battery
terminal at this step.
Screw
Lift
Figure 4
Bus Bar
Figure 5 Vehicle Front
Vehicle
Front Black
Cable
Firewall
Red
Cable

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7. Take off the front fascia by removing six hexagonal
screws (PN 7518529) and four screws
(PN 7519650). Figure 7.
8. Mount the winch plate onto the vehicle with four
screws (PN 7519372) and lock nuts (PN 7547423).
Figure 8.
Figure 7
6. Detach the plastic plate by removing two screws
(PN 7518980). Figure 6.
Figure 6
Hexagonal
Screw
Screw
Lock Nut
Screw
Screw
Figure 8

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9. Connect the wires to the winch before installing it
onto the vehicle. Figure 9.
NOTE: Connect blue wire to the blue terminal and
yellow wire to the yellow terminal (color coding is
already provided on winch). Figure 9.
Figure 9
Figure 11
10. Slide winch (PN 2204688 and PN 2204855) from
left to right direction on the plate. Figure 10.
11. Mount and x the winch (PN 2204688 and
PN 2204855) onto the plate with four screws
(PN 7519133). Figure 11.
Figure 10
Slide
Blue Wire
Yellow Wire
Screw

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13. Front Plate Bracket installation:
a) For 3500 Winch: Install the front plate bracket
(PN 5257963) with roller fair lead (PN 2411848) as
subassembly on the vehicle with the four bolts
(PN 7519072) and nuts (PN 7547441).
Figure 14.
b) For 4500 Winch: Install the front plate bracket
(PN 5258106) with fair lead (PN 2879148) as
subassembly on the vehicle with the four bolts
(PN 7519072) and nuts (PN 7547441).
Figure 15. Figure 14
Figure 15
12. Lead mounting:
a) For 3500 Winch: Mount the roller fair lead
(PN 2411848) onto the front plate bracket
(PN 5257963) with two screws (PN 7519372) and
nuts (PN 7547423). Figure 12.
b) For 4500 Winch: Mount the fair lead (PN 2879148)
onto the front plate bracket (PN 5258106) with the
two screws (PN 7517358) and nuts
(PN 7547423). Figure 13.
Figure 12
Figure 13
Fair Lead
Front Plate Bracket
Front Plate
Bracket
Roller
Fair Lead
Screw
Screw
Bolt
Bolt

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14. Cable installation:
a) For 3500 Winch: Twist the knob on the winch
(PN 2204688) and insert the cable through front
plate bracket (PN 5257963) and roller fair lead
(PN 2411848) to move the cable freely. Figure 16.
b) For 4500 Winch: Twist the knob on the winch
(PN 2204855) and insert the cable through front
plate bracket (PN 5258106), fair lead (PN 2879148)
and rubber stop (PN 5414619) to move the cable
freely. Figure 17.
Figure 16
Figure 17
Knob
Stop
Rubber
Pull
Knob
Pull

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Figure 19
15. Hook attachment:
a) For 3500 and 4500 Winch: Attach the hook
(PN 2411836) with the cable by inserting the clip
through it. Figure 18 and Figure 19.
Figure 18
Attachment
Point to Vehicle
Hook
Attachment
Point to Vehicle
Hook

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Figure 22
17. Connect the blue (PN 4013469), yellow
(PN 4013468), red (PN 4013471) and black wires
(PN 4013470) to the contactor terminals and put
the caps. Figure 21.
NOTE: Color coding for terminals will be on
contactor (PN 4013465).
18. Hook up the negative (black) (PN 4013470) and
positive (red) (PN 4013471) terminals to the bus
bar. Figure 22.
Figure 21
16. Mount the winch contactor (PN 4013465) on the
rewall with the four bolts (PN 7519330) at the
specied drilled holes. Figure 20.
NOTE: Ensure that the yellow color code on the
contactor is on top.
Figure 20
Positive Red
Negative Black
Black Wire
Blue
Wire
Red
Wire
Yellow
Wire
Bolt

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19. Feed the socket wires from inside of cab through
the grommet in the rewall. Figure 23.
NOTE: Socket position may change as per
requirement.
Figure 23
Figure 25
20. Plug in the socket wire connector to the contactor
connector (PN 4013465). Figure 24.
21. Connect the red socket wire to the accessory bus
bar. Figure 25.
Figure 24
Bus Bar
Red Wire
Contactor
Grommet
Firewall
Cabin
Socket Wire
For 3500 Winch
ACC
GND BAT

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Figure 28
23. Route the wire from fairlead to the auto-stop control
unit. Figure 27.
NOTE: Use panduit straps to secure the cable from
hot or moving parts.
24. Route the cable (highlighted) from auto-stop control
unit to the bus bar. Figure 28.
NOTE: Use red ring terminal adapter in part
number 2879148 and connect it to terminal to acc
location on bus bar. Install the black ring terminal to
the negative location on the buss bar.
Figure 27
22. Connect the connector from fairlead to auto stop
control unit connector. Figure 26.
Figure 26
Cable
Auto-stop
Control Unit
Fairlead
Control Unit
Connector
Fairlead
Connector
For 4500 Winch
Cable

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25. Route the cable from auto-stop control unit to the
socket wire connector (PN 4014228). Figure 29.
Figure 29
Figure 31
26. Route the cable (highlighted) from auto-stop control
unit to the contactor. Figure 30.
27. Cut out a hole in the din box for mounting the
socket (PN 4014228). Figure 31.
NOTE: Follow the instruction on the back of the din
for the cutout.
NOTE: Position may change as per requirement.
Socket
Winch
Hole
Firewall
Auto-stop
Control Unit
Contactor
Connector
Socket
Winch
Bus Bar
Firewall
Cable
Socket Wire
Connector
Cable
Bus Bar
Auto-stop
Control Unit
Figure 30
For 3500 and 4500 Winch Kits:

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P/N 9924528 Rev 03 01/14
29. Attach socket (PN 4014228) onto the din box with
two bolts (PN 7518980) and two nuts
(PN 7547427), at specied position.
30. Install the remote with the socket which is attached
to the din box. Figure 33.
31. Connect the negative and positive cable to the
battery which was disconnected in Step 1.
32. Attach the front fascia, center hood, center console,
shift lever housing with cap and nally install the
seat to its position which were disconnected in
Steps 7, 2, 4, 3 and 1 respectively.
Figure 33
28. Drill the mounting holes to the specied location
around the cut out of the socket on the back of din
box. Figure 32.
NOTE: Use 1/4” drill bit.
Figure 32 Hole in din box
Mounting
hole in
socket
Bolt