Polaris 4500 HD 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 Harness Adapter 2413447
2 1 Dash Switch 4015688
3 1 4500 Winch Assembly 2636470
4 1 Fairlead Mounting Bracket 5258106
51 Fairlead 2411847
6 1 Winch Hook 2411836
7 1 Winch Mounting Bracket 5257962
8 1 Contactor (Included on winch assembly) 4015600
Instr 9929139 Rev 01 2018-08 Page 1 of 13
P/N 2883860
POLARIS®® 4500 HD WINCH KIT

Instr 9929139 Rev 01 2018-08 Page 2 of 13
REF QTY PART DESCRIPTION PART NUMBER
9 1 Winch Cable 2878889
10 1 Battery Cable, Positive 4018231
11 1 Battery Cable, Negative 4018231
12 1 Winch control Harness 2414804
13 6 Screw - CAR, M10 X 1.5 X 25 7519372
14 4 Screw - M12 X 1.75 X 25 7519072
15 4 Screw - HXFL, M8 X 1.25 X 20 7519133
16 2 Nut, Battery Cable 7547270
17 4 Locking Nut - M12 X 1.75 7547441
18 6 Locking Nut - M10 x 1.5 7547423
1 Instructions 9929139
TOOLS REQUIRED
• Safety Glasses
• Drill
• Drill Bit: 1/4” (6mm)
• Pliers, Push Pin Rivet
• Pliers, Side Cutting
• Socket Set, Hex Bit, Metric
• Socket Set, Metric
• Socket Set, Torx®Bit
• Torque Wrench
• Wrench Set, Metric
IMPORTANT
Your Polaris®4500 HD 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 48 minutes
NOTE
Additional time may be required for optional steps, or
to accommodate other installed accessories.

Instr 9929139 Rev 01 2018-08 Page 3 of 13
INSTALLATION INSTRUCTIONS
CAUTION
BEFORE STARTING INSTALLATION, always
ensure vehicle is properly secured on a flat stable
surface to avoid accidental tipping, unwanted
movement and to prevent personal injury and/or
damage to equipment. Shift vehicle transmission into
“PARK”. Turn key to “OFF” position and remove from
vehicle.
1. DISCONNECT BATTERY.
WARNING
ALWAYS disconnect black negative (-) cable from
battery FIRST. Failure to do so 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.
a. Lift the driver side seat latch Alocated behind
seat bottom and remove the driver seat B. Set
seat aside for later reinstallation.
b. Remove battery access panel Cto access the
battery terminals.
c. Disconnect black negative (-) cable from
battery FIRST.
d. Next, disconnect red positive (+) cable from
battery.
2. REMOVE HOOD.
a. Rotate the two hood latches to release the
hood. Pull the hood forward and up to remove
from vehicle.
3. REMOVE WINCH COVER.
a. Remove lower front winch cover Aby
removing four push rivets B.

Instr 9929139 Rev 01 2018-08 Page 4 of 13
4. INSTALL WINCH ASSEMBLY.
a. Slide winch mounting bracket uinto position
from the passenger side as shown. Orient and
align winch mounting bracket to front
suspension bracket and steering bracket as
shown. Secure into position with provided
carriage bolts fand locking nuts l. Torque
fasteners to below specification.
TORQUE
30 ft. lbs. (40.7 Nm)
b. Slide and position winch assembly eonto the
winch mounting bracket as shown. Ensure
mounting holes on winch assembly and
mounting brackets are aligned. Use provided
fasteners hto secure winch assembly onto
winch mounting bracket. Torque fasteners to
below specification.
TORQUE
16 ft. lbs. (21.7 Nm)
5. INSTALL FAIRLEAD ASSEMBLY.
a. Install fairlead tto fairlead mounting bracket
rusing the provided screws fand locking
nuts l.
TORQUE
16 ft. lbs. (21.7 Nm)
b. Install fairlead mount bracket iwith fairlead to
suspension bracket with four screws oand
nuts uas shown.
TORQUE
24 ft. lbs. (32.5 Nm)

Instr 9929139 Rev 01 2018-08 Page 5 of 13
6. INSTALL WINCH HOOK.
a. Shift winch into “neutral” and pull rope/cable o
6-12" (15-30 cm) out through fairlead. Install
hook yto the rope/cable by inserting clevis pin
through hook and rope/cable and securing with
a cotter pin.
7. INSTALL DASH SWITCH.
a. Remove dash switch panel Aby gently pulling
out along the edges. Once dash panel is out,
remove switch plug B.
b. Install dash switch winto the mounting hole by
pressing the switch firmly into position until it is
fully seated as shown.
8. CONNECT ALL ELECTRICAL COMPONENTS.
NOTE
Refer to the Electrical Connection Reference Guide
section at the back of the instruction manual for
images and detailed harness connection illustrations
to aid in the remaining electrical connections.
IMPORTANT
When making connections, ensure all wires are
routed and secured with cable ties away from all
heat sources, moving components and sharp edges.
Failure to do so may cause damage to electrical
wires and/or underlying components which may
cause the winch to malfunction.
a. Locate the dash switch connector (12F) and
connect it to the dash switch was shown.
Once connected, reinstall dash switch panel by
aligning all mounting tabs with corresponding
slots and firmly press back into the original
position.
b. Locate the winch contactor connector (12D)
and connect it to the control box connector
(12E) located towards the rear right hand side
of the winch.

Instr 9929139 Rev 01 2018-08 Page 6 of 13
c. Next connect the pulse bar dash switch
connector (12A) to the pulse bar connection A
as shown. For MY19 and newer vehicles skip
step 8c and proceed to step 8d.
NOTE
For MY18 and older vehicles that are equipped with
a busbar style electrical power distribution strip you
will also need to connect the busbar adapter. Refer
to the image and procedures outlined in step 8d for
busbar connections.
d. For vehicles with a busbar you will need to first
remove the cable connection nut Efrom the
keyed power terminal Band install the orange
wired terminal (1B) on the busbar harness
adapter onto the keyed power terminal Bof
the busbar. Reinstall the cable connection nut
Eand torque to specification provided.
TORQUE
36 in. lbs. (4.1 Nm)
Remove the cable connection nut Efrom the
negative terminal on the busbar and install the
black wired terminal (1C) on the busbar
harness adapter onto the negative terminal of
the busbar and loosely reinstall the cable
connection nut E.
Next, remove the cable connection nut from the
positive terminal on the busbar and install the
red wired terminal (1D) on the busbar harness
adapter onto the positive terminal of the busbar
and loosely reinstall the cable connection nut
E.
e. Route the fuse block (12G) behind the pulse
bar/busbar and fasten to firewall by using a drill
and 1/ 4” drill bit to drill out the dimpled hole
location as shown in image 8c.

Instr 9929139 Rev 01 2018-08 Page 7 of 13
f. Connect the red positive (+) and black negative
(–) power cables to the corresponding positive
(+) and negative (–) terminals on the pulse bar
or busbar.
MY 19 and newer vehicle use the provided
cable connection nuts jto secure the power
cables in place as shown below. Torque to
specification provided.
TORQUE
24 in. lbs. (2.8 Nm)
MY18 and older you will need to route and
secure the red positive (+) and black negative
(–) power cables with the existing cable
connection nuts to the corresponding positive
(+) and negative (–) busbar terminals as shown
in the image below. Torque all nuts to
specification provided.
TORQUE
36 in. lbs. (4.1 Nm)
g. Ensure all wires are secured in place away
from all moving parts, sharp edges and heat
sources with provided cable ties.
9. CONNECT BATTERY.
WARNING
When BOTH battery cables are disconnected
ALWAYS reconnect AND tighten red positive (+)
cable to battery FIRST. Failure to do so 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.
a. Reinstall red positive (+) cable to positive (+)
battery terminal.
b. Reinstall black negative (–) cable to negative
(–) battery terminal.
c. Reinstall battery access panel C.

Instr 9929139 Rev 01 2018-08 Page 8 of 13
10.REINSTALL SEAT.
a. Lift the driver side seat latch Alocated behind
seat bottom and firmly press down on seat
bottom to reinstall the driver seat B. Once
installed, pull forward on the seat back to
ensure the seat is fully latched and secured
into position.
11. REINSTALL WINCH COVER.
a. Reinstall lower front winch cover Awith the
previously removed four push pin rivets B.
12.REINSTALL HOOD.
a. Place hood into position and rotate the two
hood latches to secure into position.
13.VERIFY WORK.
a. Confirm all electrical wires/connections have
been routed and connected per instructions.
b. Confirm that there are no exposed wires or
terminals.
c. Ensure all loose wires are secured away from
moving parts, sharp edges and heat sources.
14.VERIFY WINCH FUNCTION.
WARNING
BEFORE testing winch function, read the Operator’s
Manual that came with your winch. ALWAYS abide
by ALL safety warnings and operating procedures
outlined in the Operator’s Manual. Failure to comply
may result in serious injury or death.
a. With the vehicle key in the “ON” position, check
winch for proper operation using the installed
dash switch.
i. Shift winch from “FREE” to “LOCK” and
verify proper function.

Instr 9929139 Rev 01 2018-08 Page 9 of 13
WINCH OPERATION
GEAR SELECTION
The Polaris 4500 HD winch is equipped with two
different gear settings. “FREE” and “LOCK”.
WARNING
DO NOT attempt to shift the winch while the rope/
cable is under tension. ALWAYS make sure the
winch rope/cable is not in tension before shifting the
winch between gears to avoid damage to the winch
mechanism. Failure to comply may lead to death or
serious personal injury
• The “FREE” setting is meant to be used to free-
spool the winch rope/cable for faster deployment.
To shift into “FREE”, rotate the gear selection
handle counter-clockwise.
• The “LOCK” position is meant to be used when
winching is required or to retract the cable/rope
back onto the winch spool. To shift into “LOCK”,
rotate the gear selection handle clockwise.
WIRELESS REMOTE OPERATION
(IF EQUIPPED)
NOTE
The remote will automatically turn itself off after 30
seconds of inactivity. You will therefore need to turn
the remote back on if it has been more than 30
seconds since the prior use.
• When properly installed, the wireless remote will
allow you to operate the winch from off the vehicle,
which can be a safe way to operate the winch when
done properly.
• To turn on the wireless remote, hold the small "On/
Off" button for three seconds or until the LED light
on the remote turns on. If the vehicle is on so that
the winch is receiving power, the wireless remote
should operate the winch as if you were using the
winch switch located on the handlebar. If the remote
is not operating properly, see the troubleshooting
information at the end of the instructions.
• To manually turn off the remote, hold the small "On/
Off" button for 3 seconds or until the LED light turns
off. The remote will automatically turn itself off after
30 seconds of inactivity.
• See the illustration below for proper wireless remote
operation.
AUTOSTOP OPERATION (IF EQUIPPED)
• The Autostop system is meant to help prevent
damage to the winch system from over-tightening of
the rope/cable, but is not meant to prevent all
foreseeable winch damage. The winch is very
powerful and care should be exercised whenever it
is in operation. The winch operator is always
responsible for using the winch properly and the
Autostop system should only be used as a
secondary preventive measure to help prevent
damage to the winch from over-tightening the rope/
cable.
• The Autostop system works when the black rubber
puck nears the aluminum fairlead. Stop magnets in
the puck trigger sensors in the fairlead, which
prevent the contactor from pulling in the winch rope/
cable any further. During final inspection, confirm
that the Autostop is functioning properly.
• Troubleshooting steps are given in that section to
help diagnose and correct any problems.

Instr 9929139 Rev 01 2018-08 Page 10 of 13
TROBLESHOOTING
SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION
Dead vehicle
battery
Incorrect, damaged, or
corroded electrical
connections
Verify all winch electrical connections are per instruction
manual and free of damage and/or corrosion.
Winch will not
operate
Contactor not receiving
power
Turn vehicle key on.
Wireless remote not
powered on
Turn wireless remote on.
Incorrect, damaged, or
corroded electrical
connections
Verify all winch electrical connections are per instruction
manual and free of damage and/or corrosion.
Keyed power circuit
(orange wires) not
properly powered
Check 10A accessory circuit fuse for continuity; replace as
required.
Winch operates in
one direction only
Autostop fairlead not
properly connected
If winch operates only outward then ensure magnetic stop
(black rubber puck) is not touching autostop fairlead.
If winch operates inward even when magnetic stop is
touching fairlead then verify all winch electrical connections
are per instruction manual and free of damage and/or
corrosion.
Winch makes noise
but rope does not
move
Contactor powered, but
not winch
If clicking sound is heard when winch control button is
depressed, but winch motor is silent, then verify electrical
connections between winch and contactor are free of
damage and/or corrosion.
If winch makes noise but does not move, verify winch is in
gear.
If winch is in gear, but winch still does not move, have a
dealer inspect the winch.
Winch not in proper
gear
Rotate gear knob fully into L or H, then recheck.
Winch operates too
slowly
Winch is improperly
loaded
Verify rope/cable is not binding on spool or fairlead.
Winch will not
change gears
Rope/cable is under
load
Changing gears while under load is intentionally difficult to
prevent accidental operation, which could lead to personal
injury or winch failure. Ensure rope is under no tension, and
rope is not binding on spool or fairlead. Briefly operate winch,
then attempt to shift again.

Instr 9929139 Rev 01 2018-08 Page 11 of 13
SERVICE KITS
Winch Hardware Kit: PN 2206300
REF QTY PART DESCRIPTION
1 4 Screw, HXFL - M12 X 1.75 X 25
2 4 Screw, HXFL M8 X 1.25 X 20
3 6 Screw, Carriage - M10 X 1.5 X 25
4 6 Locking Nut - M10 X 1.5
5 4 Locking Nut - M12 X 1.75
6 2 Hex Nut - M6 , Serrated
HD Service Handle Kit: PN 2205265
REF QTY PART DESCRIPTION
1 1 4500 HD Service Handle
2 1 Mounting Screw
Autostop Service Kit: PN 2881288
NOTE
The Autostop kit is compatible with the Polaris 4500
HD winch kit and is available for purchase
separately.
REF QTY PART DESCRIPTION
1 1 Control Box
2 1 Autostop Fairled
3 1 Rubber Puck
4 2 Routing Clip
5 2 Screw, SH - M10 X 1.5 X 25
6 2 Screw, HXFL - M10 X 1.5 X 30
7 2 Screw, TRX - #10 X 5/8
8 2 Locking Nut, M10 X 1.5

Instr 9929139 Rev 01 2018-08 Page 12 of 13
Universal Wireless Remote Kit: PN 2881287
NOTE
The Universal Wireless Remote kit is compatible
with the Polaris 4500 HD winch kit and is available
for purchase separately.
REF QTY PART DESCRIPTION
1 1 Wireless Receiver
2 1 Wireless Remote
3 1 Wireless Remote Holder
4 2 Routing Clip
56 Screw - #10 x 3/4
6 2 Screw - M6 X 1.0 X 25

Instr 9929139 Rev 01 2018-08 Page 13 of 13
ELECTRICAL REFERENCE GUIDE
Harness Adapter Detail (MY18 and older) Winch Harness Detail
FEEDBACK FORM
A feedback form has been created for the installer to provide any comments, questions
or concerns about the installation instructions. The form is viewable on mobile devices
by scanning the QR code or by clicking HERE if viewing on a PC.
FEEDBACK FORM