Polaris PRO 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 Handlebar Switch 2205636
2 1 Control Box 2413444
3 1 Wireless Remote Kit 2879316
4* 5Panduit Strap -
5* 4Screw, Hex Flange - M8 X 1.25 X 25 -
6 1 Mounting Bracket 1022577
71 Winch - 35 HDDS 2206383
8 1 Hook, Winch Latch 2411836
Instr 9927474 Rev 01 2017-02 Page 1 of 14
P/N 2882241
SPORTSMAN®XP POLARIS®PRO HD
WINCH KIT

Instr 9927474 Rev 01 2017-02 Page 2 of 14
REF QTY PART DESCRIPTION PART NUMBER
9 1 Rope 2878888
10 1 Winch Cable, Yellow 6 GA 300mm 4013468-300
11 1 Winch Cable, Blue 6 GA 300mm 4013469-300
12 1 Power Cable, Black #6 530mm 4013470-530
13 1 Power Cable, Red #6 510mm 4013471-510 WC
14 1 Contactor 4015095
15 1 Autostop Fairlead 5140385
16 1 Stop Magnet 5415787
17 4 Screw Torx®Head - M8 X 1.25 X 20 -
18* 2 Screw - M6 X 1.0 X 25 -
19* 2 Screw - M10 X 1.5 X 25 -
20* 2 Nut - M10 X 1.5 -
1 Winching Guide 9923644
1 Instructions 9927474
Service Handle (includes freespool handle and screw) 2205265
Items marked (*) are included in Hardware Kit (PN 2880643).
TOOLS REQUIRED
• Safety Glasses
• Socket Set, Metric
• Screwdriver, Phillips
• Wire Cutter
• Hex Key Set, Metric
• Socket Set, Torx®Bit
IMPORTANT
Your SPORTSMAN®XP POLARIS®PRO 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 40 minutes

Instr 9927474 Rev 01 2017-02 Page 3 of 14
INSTALLATION INSTRUCTIONS
NOTE
This kit contains the same components as
Sportsman (non-XP) winch kit (PN 2882242), but
have been pre-assembled differently. If you need to
install this kit on a Sportsman (non-XP) vehicle, refer
to image below that shows the contactor location
and wire routing for Sportsman (non-XP) winch kit,
and reassemble the contactor and wiring to match
below image. You will need to download instructions
manual (PN 9927475) and follow those instructions
for final installation.
*ABOVE IMAGE REFERS TO KIT PN 2882242
PREPARATION
1. Place vehicle in “PARK”. Turn key to “OFF”
position and remove from vehicle.
2. Detach rubber latch Aon both sides of vehicle
and open the front rack B.
3. Rotate two latches and remove storage tray C
from vehicle as shown.
4. Disconnect the black (negative) Eand red
(positive) Dcables from the battery.
WARNING
ALWAYS disconnect black negative (-) cable from
battery FIRST. Failure to do so will result in high
current electrical arc, and may result in battery
explosion if tool touches grounded frame. Death or
serious personal injury may occur.

Instr 9927474 Rev 01 2017-02 Page 4 of 14
5. Remove the accessory front brushguard from
vehicle (if equipped).
6. Remove the lower front bumper cover Fby
removing four bolts G. Retain bolts for use during
reinstallation.
7. Remove the winch cover Hfrom the front lower
bumper cover Fby removing two push pin rivets
J. The winch cover and push pin rivets will not be
needed while the winch is installed on the vehicle.
NOTE
Your vehicle’s factory tool kit contains a pliers
specifically designed for the removal of push pin
rivets. See photo below.
NOTE
Before installing the winch kit add or replace the
proper front gearcase fluid as required per your
vehicles service manual as this process will be
difficult to do after the winch is installed.
WINCH INSTALLATION
NOTE
See the Electrical Connections Reference Guide
section of the instruction manual for detailed photos
of each part and their respective connections.
1. Check and confirm wire routing and connections
are as shown below and make any necessary
adjustments before moving to next installation
steps. Locate white contactor connection Mon the
winch assembly. If it is secured to the winch
assembly with a plastic tie, cut the tie to allow the
wires to be routed properly while installing the
winch assembly.

Instr 9927474 Rev 01 2017-02 Page 5 of 14
2. Install winch assembly uto chassis frame K
using four screws tas shown. Check that all
wires are free to move and not pinched between
the vehicle chassis and the winch assembly.
Torque screws to specification.
TORQUE
20 ft. lbs. (27.1 Nm)
3. Route red (positive) fand black (negative) d
winch cables to the battery as shown. Attach
cables to chassis frame at required locations using
cable ties. DO NOT CONNECT TO BATTERY AT
THIS TIME.
4. Locate the vehicles main harness winch contactor
connection on the frame tube of the vehicle behind
the front left tire as seen in the photo below.
Remove cap from main harness connector and
connect the wire harness splitter ethat came with
your kit to the white contactor connection as
shown in the top photo of the Electrical
connections Reference Guide. Do not connect any
other connections at this time.

Instr 9927474 Rev 01 2017-02 Page 6 of 14
CONTROL BOX INSTALLATION
1. Position control box on the left side of the vehicle
behind the radiator as seen in the photo below.
Connect white electrical connectors for the control
box as seen in the top photo of the Electrical
Connections Reference Guide.
2. Route power wires to the battery area and connect
the red or orange wire from the control box to the
orange wire on the vehicles main wire harness as
seen below. Route black wires from control box w
to black (ground) terminal on battery but DO NOT
CONNECT TO BATTERY AT THIS TIME.
WIRELESS REMOTE RECEIVER INSTALLATION
1. Mount wireless remote receiver eonto cab
support bracket Nusing provided cable ties as
shown.
2. Connect white electrical connectors as seen in the
top photo of the Electrical Connections Reference
Guide. Route power wires to battery area and
connect red or orange wire on control box to
orange wire on the vehicles main wire harness as
seen below. Route the black wires from the control
box to the wto the black (ground) terminal area
on the battery but DO NOT CONNECT TO THE
BATTERY AT THIS TIME.

Instr 9927474 Rev 01 2017-02 Page 7 of 14
3. Secure all remaining wires to the vehicles main
wire harness as shown.
HANDLEBAR SWITCH INSTALLATION
1. Install the handlebar switch qusing supplied
screws Pon handlebar as shown. Torque screws
to the specification listed below being careful not
to overtighten..
TORQUE
2 ft. lbs. (2.7 Nm)
2. Connect handlebar switch connector Qto the
vehicle main wire harness as shown.
WIRELESS REMOTE HOLDER INSTALLATION
1. Wireless remote holder can be installed in desired
location on vehicle. Use the screws provided in the
wireless remote kit for holder installation. For your
reference see the photo below for possible
mounting location of wireless remote holder.
FINAL INSPECTION
1. Confirm all the wiring is correct.
2. Confirm that there are no exposed wires or
terminals.
3. All loose wires need to be wrapped tight and
secured away from moving parts and heat
sources.

Instr 9927474 Rev 01 2017-02 Page 8 of 14
REINSTALLATION
1. Reinstall the front bumper cover Fon vehicle
using retained screws G.
2. Reinstall accessory front brushguard (if equipped).
3. Reinstall red Dand black Ecables to battery
terminals along with winch power cables f d
using screws L. Also, connect black wires on
remote box eand control box wto battery
negative (ground) terminal.
4. Reinstall storage tray Con the vehicle.
5. Close the front rack Band secure in place using
rubber latches A.
6. With the vehicle key in the “ON” position, check
winch for proper operation.
Test function of Autostop feature. When reeling in
the winch rope, confirm that the winch will turn off
automatically when the rubber puck reaches the
aluminum fairlead. The winch should not allow the
rope to be reeled in once the rubber puck has
come within a close proximity (typically 1” or less)
or made contact to the fairlead. If the Autostop is
not functioning properly, see troubleshooting
information at the end of the instructions.
HANDLEBAR SWITCH OPERATION
• When properly installed, the handlebar switch
allows you to operate the winch while seated on the
vehicle. See the illustration below for proper switch
operation.

Instr 9927474 Rev 01 2017-02 Page 9 of 14
WIRELESS REMOTE OPERATION
• 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 use 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 qlocated on the handlebar. If the
remote is not operating properly, see the
troubleshooting information at the end of the
instructions.
• 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.
• 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
The Autostop system is meant to help prevent
damage to the winch system from over-tightening of
the rope, 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.
The Autostop system works when the black rubber
puck nears the aluminum fairlead h. Stop magnets j
in the puck trigger sensors in the fairlead, which
prevent the contactor from pulling in the winch rope
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.
GEAR SELECTION
WARNING
Attempting to shift the winch while the rope is under
tension is dangerous and can result in injuries or
death. Make sure the winch rope is not in tension
before shifting the winch between gears.
Your winch is equipped with three different gear
settings. High, Neutral and Low. When in neutral the
“N” marking will show thru the cutout window on the
shift knob. See photo below.

Instr 9927474 Rev 01 2017-02 Page 10 of 14
The high gear setting is meant for rapid recovery
mode only and should not be used while the rope is
under load. To shift into high gear, rotate the gear
shifting knob clockwise until the “H” marking shows
thru the cutout window on the shift knob. See photo
below.
NOTE
High gear is for rapid recovery of the winch rope
only. It is not intended for pulling and will reduce the
life of the winch if used under load.
To shift into low, rotate the gear shifting knob counter-
clockwise until the “L” marking shows thru the cutout
window on the shift knob. See photo below.
RAPID RECOVERY WINCH FUNCTION
Your winch is equipped to quickly reel in the winch
rope when being used under no-load conditions.
Using this feature will significantly reduce the time it
takes to rewind your rope after use.
When to use
Use Rapid Recovery to quickly reel the rope in or out
to speed up the recovery process. The rope speed is
approximately five times the speed of standard
operation, so caution should be taken to always reset
the winch to “Low” gear after using the Rapid
Recovery so the speed of the winch will not take the
operator by surprise. Do not pull loads while in Rapid
Recovery gear.
How to shift
To operate the Rapid Recovery, make sure the winch
is not in operation and the rope is not in tension.
Rotate the shift knob fully clockwise to engage “High”
gear (Rapid Recovery). Pulling slightly on the winch
rope by hand will help the gears align and the shift to
be completed. Use Rapid Recovery only to reel in the
rope with “No Load”, then rotate the shift knob back to
“Low” gear (standard operating mode) by rotating the
knob back fully counter-clockwise.
WARNING
Attempting to shift the winch while the rope is under
tension is dangerous and can result in injuries or
death. Make sure the winch rope is not in tension
before shifting the winch between gears.

Instr 9927474 Rev 01 2017-02 Page 11 of 14
TROUBLESHOOTING
If your winch/Autostop is not functioning properly, below is a short guide that can help you diagnose and correct
the problem.
SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION
Dead Vehicle Battery Check to ensure that both the
wireless remote receiver and
control box power wires are
connected to keyed power and not
directly to the positive battery
terminal.
Rewire to ensure wiring is
connected properly per
instructions.
Winch will not operate Contactor not receiving power Turn vehicle key on.
Wireless remote not powered on Turn wireless remote on.
Connections between components
not in proper order
Check connections. Connect wired
handlebar switch connection from
vehicle main wire harness directly
to contactor to make sure a direct
connection will operate the winch.
If connections are not in the order
shown on the pictures in the last
page, the whole system may not
function or only certain parts of it
will function.
Keyed power circuit (orange wires)
not properly powered
Check fusebox for 10A accessory
circuit. Check voltage in certain
places, especially orange wires
coming out of the main harness by
the steering post.
Winch operates in one direction
only
Autostop fairlead not connected
properly
Check connections. If winch
operates only outward, check that
the black rubber puck is not
touching the aluminum fairlead. If
winch operates inward even when
puck is touching fairlead, check
connections of the Autostop control
box. If winch operates inward but
not outward when rubber puck is
touching fairlead, check color of
wires at connectors to make sure
they match on both sides of the
connection (in case two wires have
been switched in the connector).
Winch makes noise but rope does
not move
Contactor powered, but not winch If you can hear a clicking sound
when you press the winch control
but the winch does not make any
sounds, check the connections
between the winch and the
contactor. If the winch makes noise
but does not move, check that the
winch is in gear. If the winch is in
gear and the winch does not move,
have a dealer inspect the winch.

Instr 9927474 Rev 01 2017-02 Page 12 of 14
SYMPTOM POSSIBLE CAUSES RECOMMENDED SOLUTION
Winch makes noise but rope does
not move
Winch not in proper gear Rotate gear knob fully into L or H,
then recheck.
Winch operates too slowly Winch in wrong gear Rotate gear knob into proper gear,
then recheck.
Winch improperly loaded The winch operates slowly in Low
gear. In High (Rapid Recovery),
the winch operates quickly but can
be slowed if there is a load on the
rope or if the rope is bound up
inside the spool area. Check that
the winch is clear and the rope is
not bound up and that there is no
load pulling on the rope.
Winch will not change gears Rope is still under load The gears are purposely hard to
shift when a load is on the rope to
prevent accidental operation,
which could lead to winch failure or
personal injury. Make sure the rope
has no load in tension, then check
that the rope is not bunched up
and bound inside the spool area.
Operate the winch for a short
period, then attempt to shift again.

Instr 9927474 Rev 01 2017-02 Page 13 of 14
ELECTRICAL CONNECTIONS REFERENCE GUIDE
Winch with auto fairlead, wireless remote, and handle bar switch
Winch with auto fairlead and handle bar switch
Winch with roller fairlead and handle bar switch

Instr 9927474 Rev 01 2017-02 Page 14 of 14
9927474 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