WARN ProVantage 2500-s - Manual (Page 6)

WARN INDUSTRIES
11 89294A0
MOUNTING
Step 5 - Mount the Dash Switch
(optional on UTV models)
WARNING To prevent severe injury or death.
Always verify area is clear of fuel lines, fuel tank, brake
lines, electrical wires, etc., when drilling.
WARNING To prevent serious injury or death from
electrical fi re:
Never route electrical cables across sharp
edges.
Never route electrical cables near parts that
get hot.
Never route electrical cables through or near
moving parts.
Avoid pinch and wear/abrasion points when
installing all electrical cables.
1. Determine the dash mounting location for
the dash switch (location is pre-determined
on some specific models). Mount switch
using bracket and supplied fasteners or cut
rectangle slot as shown in Figure 10.
2. Route the wire harness to where the
contactor will be mounted.
3. See wiring diagram provide, with contactor,
for switch wiring detail.
NOTE: If installing both switches, both 20 gage
red wires MUST be spliced to a key controlled
accessory circuit of the ATV/UTV as described in
step 4, page 9.
Figure 9 and 10 Dash Mount Installation
Not to scale. Do NOT use as a template!
21.1mm
(.83in.)
36.8mm
(1.45in.)
#10x5/8 in. sheet metal screw OR
M5x0.8 hexhead capscrew, M5-0.8
nut, washers.
WARN INDUSTRIES
89294A0 12
ELECTRICAL CONNECTIONS
Step 6 - Install the Wiring
WARNING To prevent serious injury or death.
Always place the supplied terminal boots on wires and
terminals as directed by the installation instructions.
All wires must be attached to the contactor before
mounting the contactor to the ATV/UTV.
WARNING To prevent serious injury or death from
electrical fi re:
Never route electrical cables across sharp
edges.
Never route electrical cables near parts that
get hot.
Never route electrical cables through or near
moving parts.
Avoid pinch and wear/abrasion points when
installing all electrical cables.
WARNING Always insulate and protect all
exposed wiring and electrical terminals.
1. Slip terminal boots on yellow and blue cable
ends. See Figure 11 on following page.
2. Attach the yellow and blue electrical cables
to the motor terminals on the winch. Yellow
is marked #1 and blue is marked #2 on the
motor. Torque the terminal nuts on the
motor to 5.7 N-m (50 lb-in). Seat boots over
terminal.
3. Route the yellow and blue electrical cables
back to the contactor. Place boots over
ring terminals. Place ring terminals on color
coded contactor posts (yellow cable to yellow
post, blue cable to blue post). Install and
finger tighten nuts to retain ring terminals
on contactor posts. Do NOT tighten nuts or
seat boots at this time.
6. Install boots on ring terminal ends of red
and black cables. Place ring terminals on
color coded contactor posts (red cable to red
post, black cable to black post). Install and
finger tighten nuts to retain ring terminals
on contactor posts. Do NOT tighten nuts or
seat boots at this time. Route red and black
cables to battery. Do NOT connect cables to
battery at this time.
7. Mount the contactor to the location planned
in Step 3. Tighten contactor mounting
fasteners to 5.7 N-m or 50 lb-in.
8. Adjust cables to facilitate orderly and straight
routing of the cables from the contactor.
Avoid kinks or sharp bends in cables. Avoid
crossing cables over each other for at least
the first 6” (152mm) of cable starting from
the contactor post. Torque the contactor
terminal nuts to 4.5 N-m or 45 lb-in. Seat
boots over ring terminals and posts.
9. Carefully inspect battery and winch
electrical cable routing. Is it neat and tidy?
WARNING! Always route and secure
electrical cables away from sharp edges,
away from moving parts and away
from sources of heat. Zip tie and secure
electrical cables and wiring harness. Zip
ties should be snug, but not cutting into wire
insulation. Use electrical tape, pieces of
rubber hose or electrical conduit to protect
electrical cables and wire harness where
needed to avoid electrical cable insulation
wear or abrasion.
10. Attach battery cables, red (positive) cables
FIRST, black (negative) second. Install
boots as appropriate to protect connection.
Torque battery terminal fastener as directed
by vehicle service manual.