Winch wiring for in-line remote kit

Having trouble with your winch draining the battery? The problem may be in the way you wired your winch. If you wired the switch to be “hot” all the time (running it directly to the battery), you run the chance of operating the winch without power and draining the battery or operating the winch unintentionally.

Connect the winch switch wire to a keyed power source that is only “hot” when the ignition is on. Do not connect it directly to the battery. Wiring the winch this way is a safety issue as well as helping to prevent battery drain. By making sure the winch only receives power when the ATV is on, you prevent accidental operation by kids fooling around or someone out playing pranks.

Since an electric ATV winch requires a significant amount of power, it’s best to run the winch only when the ATV is running. You might think you’re only using a small amount of battery power, but you can easily drain the battery within a few minutes if the ATV is off.

If you want to upgrade your system with a wireless remote, use the Universal In-Line ATV Winch Wireless Remote Kit from ProMark Offroad, which includes a wireless keychain remote, receiver control box, and wiring.

Electric recovery winch wiring

To power your winch, you can either use your vehicle battery or an auxiliary battery. For light to medium duty winching, your vehicle’s battery should provide enough power. For heavy duty winching (close to the winch’s maximum capacity), we recommend installing a second battery to power the winch.

To wire a 12 volt electric winch using your vehicle’s battery, follow these steps. For more specific directions, see the instruction manual provided with your winch.

1. Run the positive wire to the positive terminal on the winch.
2. Run the negative wire to the negative terminal on the winch.
3. Route both wires to the engine, making sure the wires will not get pinched or come in contact with any hot spots.

Now you’re ready to work under the hood.

1. First, connect the positive lead from the winch to the positive terminal on the battery. Use an in-line circuit breaker if needed.
2. Next, connect the negative lead from the winch to the negative terminal on the battery.

If you plan to take your recovery winch on and off (for example, with a mobile mount), you can make it easier on yourself by installing a quick connect setup. Make sure the quick connects are approved for use with the gauge of wire used in your winch setup.

ATV winch installation

Before you begin installation, disconnect the vehicle ground and positive leads from the battery. Make sure your battery or power supply meets the electrical requirements for operating an ATV winch. Heavy duty winching may require an auxiliary battery and heavy duty alternator.

1. Install the mounting kit first. Mount plates are available here or from your local powersports dealer. Detailed instructions are included with your mounting kit. Read and follow these instructions carefully.

   If you choose not to purchase a mounting kit, you MUST install your winch on a flat, secure mounting location. You will also need to drill holes in the structural support of your vehicle. Your structural support MUST be able to withstand the maximum rated pulling force of the winch.

2. Line up the ATV winch with the holes in the mounting kit or structural support.

3. Secure the winch to the mounting kit or structural support with the bolts, washers, and nuts supplied with the winch. In order to gain access to the hardware directly underneath the cable drum, you may need to unspool the cable from the winch drum.

4. Drill mounting holes for the contactor. We recommend mounting the contactor in a clean, dry location (for example, in or near the rear storage box, or under the seat). Once you decide on a mounting location, drill the holes but do not install the contactor yet, as it is easier to wire the contactor before mounting.

5. Mount the thumb switch. The mounting location for the switch is typically on the left handlebar. Use a piece of black electrical tape to prevent rotation on the bar. Do not install over any wires or hoses. After you mount the switch, route the wiring harness back to where the contactor will be mounted, attaching the harness to hard points on the vehicle with cable ties. Attach the wires according to the instructions in your ATV winch manual.

6. Attach the battery wires to the contactor, but do not hook up to the battery yet.

7. Install the winch wires to the contactor and winch as instructed in your manual.

8. Secure the contactor to your chosen mounting location. When all wires have been properly routed and secured with cable ties and electrical tape, take a minute to ensure that your system is properly installed and free from restrictions. When installation and wiring is complete, you may reattach the wires to the positive and negative battery terminals.

Replace the cable on your winch with the same diameter and length.

When replacing the cable on your ATV or recovery winch, use the cable width and length recommended by the manufacturer. Never replace cable with heavier or lighter rope. If the cable is too thick, you won’t be able to fit as much cable on the spool. If it’s too thin, it won’t have enough strength for the load rating on the winch.

If preferred, you can switch to synthetic rope for safer winching, plus no frayed wire or kinked cable.

You do not need to remove the winch from the vehicle (unless the winch is mounted in a way that restricts access to the drum) or take the winch apart to replace the cable.

How to Replace Wire Winch Cable

1. Spool out the entire length of the old cable.
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2. Remove the winch cable where it is attached to the drum. Release the tension on the cable and push on the end of the cable where it feeds through the small hole in the drum. If the rope is kinked over and pulled tight into the drum, simply push the cable out of the hole until you can straighten out the kinked cable. Then pull the end of the cable through the hole to remove it from the drum. If the cable will not come out by pushing, try using a pin punch (or something similar) and a hammer to drive the metal button or keeper out of the hole. If your cable is attached to the drum with a bolt, you’ll need to remove the bolt to take off the cable.
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3. Attach the new cable to the drum. For wire rope, slip the end of the cable through the hole in the drum and tighten the set screw to hold the cable in place. For recovery winches, apply Loctite (or similar product) to the cable clamp thread to prevent loosening of the screw. Tighten the clamp screw (but be careful not to overtighten).
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   If you are replacing your wire cable with synthetic rope, push the end of the rope into the hole in the drum. Pull the rope through the hole, wrap it around the underside of the drum and over the top, tuck the rope underneath itself where it exits the drum, and then depress the end of the rope back into the hole in the drum. You may need to use a screwdriver to force the end of the rope into the hole.

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4. Respool the cable in the underwound direction so that the winch spools in and out correctly. Respool under a load of at least 500 pounds so that the outer layers will not draw down into the inner layers.

Honda Foreman model specific winch mount

1. Model Specific Winch Mounts

The most popular type of winch mount is a model specific plate. Model specific winch mounts are fairly easy to install. Each mount kit is designed to fit with little or no modification. Some model specific mounts may require modification for use with certain winches, but for the most part, they mount right up with no problem. ProMark uses a winch plate wizard to help you find the right mount plate based on your make and model.

2. Universal Mount Plates

If you’re skilled in metalwork and you want to customize your mounting plate, a universal winch mount might be a good option for you. The extent of modifications needed depends on your ATV/UTV model and how you decide to mount the winch. Universal mount plates are generally cheaper, but they take a lot more work to mount.



ATV receiver hitch mount

3. ATV Receiver Hitch Mounts

Sometimes a receiver hitch mount makes more sense than a frame mounted winch. The nice thing about receiver mounts is that they are easy to install and they allow you to remove the winch when it’s not needed. This lightens up the load, makes wheelies easier, and prevents theft. ATV receiver hitch mounts come in 1 1/4″ and 2″ sizes to fit the size of your receiver hitch.

Winch / Mount Plate Compatibility

Make sure the mount works with your winch—obvious enough, but some winches use a 3-bolt mounting pattern and others use a 4-bolt or 2-bolt pattern. The winch size and body style can also make a difference in whether or not it will work with the mounting plate. Because of limited mounting space on some ATVs and UTVs, trimming may be required on the mount plate or bumper in order to install the winch.

This quick connect wiring kit lets you easily connect and disconnect your ATV winch.

Ever wish you could move your winch from front to rear? Share a winch between two ATVs? Rig up a dual winch setup? With quick connect wiring, all of these are possibilities, and it won’t take long to connect and disconnect your winch whenever you need to. With a mobile winch mount and quick connect wiring, you can take your winch off when you don’t need it, move it from front to rear, and move it to another ATV.

How It Works

ATV quick connect wiring generally comes with three leads. The shortest lead (18″ for the ProMark kit) connects to the positive and negative winch terminals. The medium and long leads (30″ and 86″ for the ProMark kit) provide power to the front and back of the ATV, allowing you to hook up front and rear winches or use a mobile winch mount to move the winch from front to rear. By wiring a second ATV, you can also swap the winch between bikes.

Advantages of Quick Connect Wiring

Disconnecting the wiring, pulling a pin on the winch mount, and moving the winch takes only seconds. Removing the winch from your ATV cuts down on weight, keeps it from getting stolen, and makes it easier to do wheelies. Moving the winch from front to rear comes in handy for pulling other vehicles out of the mud and doing work around the yard.

Prevent winch theft with these ideas.

• Weld a small piece of scrap metal, a cap, or something similar over one or more of the bolts. Don’t tack weld the bolts themselves. The high heat can compromise the strength of the bolt.
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• Use Loctite(R) Threadlocker Red or a similar product to prevent tampering with the bolts. Loctite Red can only be removed by heating the parts up to 500 degrees Fahrenheit.
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• Buy a security bolt lock. Some manufacturers, such as Tuffy, sell bolt locks that can only be removed with a special key, making it nearly impossible to steal your winch.
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• Use a receiver hitch mount and quick connect wiring that allows you to take the winch off when it’s not needed. Another benefit of receiver mounted winches is that you can move the winch from front to rear, and you can use the winch on more than one vehicle.
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• Use a hidden mount for your winch. Not only is it harder to see, but it’s harder to get at. The downside is that it’s also harder for you to get at your winch when you need to.
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• Drill a small hole through the back of the winch mount and the frame. Then insert a receiver hitch lock through the holes to secure the mounting plate and bumper and prevent access to the winch bolts.

Jeep TJ Grille Mount

Grille Guard Mounts

For a front mounted winch, grille guard mounts offer the convenience of a grille guard and winch mount all in one. They give your rig a tough look, protect your front end from tree branches and other hazards, and are fairly easy to mount. One of the best features is that the winch is easy to access, making it easier to prevent cable binding and perform maintenance. Some grille guard mounts require no drilling or modifications, but others may require drilling or trimming.

Mounting Plates and Channels

One of the most cost-effective solutions is a mounting plate or channel. Most universal channels will require custom drilling and cutting to fit your vehicle. Other mount plates require no drilling and simply bolt on to the front of your vehicle. With a mounting plate or channel, your winch is easy to access and, depending on any modifications needed, should be fairly simple to install.

Mobile Hitch Mount

Hitch Mounts

Receiver hitch mounts are convenient for owners who want to take the winch off when they don’t need it. Quick connect plugs make it even easier to hook up the electrical wiring. You can also install a receiver on the front end and switch the mount between the front and rear. The biggest appeal of a hitch mounted winch is the ease of installation. With the right setup, you can share one winch among several vehicles. Since the ease of installation and removal can make your winch more vulnerable to theft, use a locking hitch pin or remove the winch and lock it up at home to prevent your winch from getting stolen.

Hidden and Semi-hidden Mounts

Hidden and semi-hidden mounts are ideal for owners who want to keep the clean look of their truck or Jeep. Mounting your winch behind the bumper requires more installation time and possibly some drilling and fabrication, but if you’re fairly mechanical, it shouldn’t be a problem. Because the winch is tucked behind the bumper, you may have a harder time accessing the winch, cable, and controls. The upside is that a hidden mount keeps your winch sheltered from the elements, out of sight, and protected from thieves.

Replacement Bumper Mounts

Another option for a winch mount is to replace the entire bumper with a prefabricated bumper and winch mount. This option provides a rock-solid mounting point, but it requires more installation time and a fatter budget. Drilling and cutting will most likely be required.