[QuadJunkie]

It's always good to have the extra time to do these type of projects.
Got the KFI part# 100545 winch mount and Superwinch LT2500 installed and
was cleaning around the wiring and found some bare wires. Not burned maybe mice?
I'm going to use liquid tape on these I think.

Also Looking to install the solenoid in the back storage box.

Got a question. Where and how do you guys attach the circuit breaker to the frame?

 

[Goober]

Ooh wee they done abraided them wires hoss. Maybe you could put a splice in there—if the wire is too small and if there’s a lotta amps moving through the remaining strands, the wire could melt or burn.

I mounted my relay behind the fuel tank under the seat

 

[shadetree]

It's always good to have the extra time to do these type of projects.
Got the KFI part# 100545 winch mount and Superwinch LT2500 installed and
was cleaning around the wiring and found some bare wires. Not burned maybe mice?
I'm going to use liquid tape on these I think.

Also Looking to install the solenoid in the back storage box.

Got a question. Where and how do you guys attach the circuit breaker to the frame?

don't know about a circuit breaker ?, warn does not have this, and I only use warn. I mount my contactor switch in the trunk, as high as I can mount it.

 

[shadetree]

yep, looks like mice had dinner on some of your wires.

 

[Goober]

It's always good to have the extra time to do these type of projects.
Got the KFI part# 100545 winch mount and Superwinch LT2500 installed and
was cleaning around the wiring and found some bare wires. Not burned maybe mice?
I'm going to use liquid tape on these I think.

Also Looking to install the solenoid in the back storage box.

Got a question. Where and how do you guys attach the circuit breaker to the frame?

Sorry I was thinking smaller relay—no

some of these new winches must have a circuit breaker built so you can cut power to the winch? Maybe mount this where you can get to it pretty easy. So you can kill the juice if the contactor sticks closed

 

[QuadJunkie]

Ooh wee they done abraided them wires hoss. Maybe you could put a splice in there–if the wire is too small and if there’s a lotta amps moving through the remaining strands, the wire could melt or burn.

I mounted my relay behind the fuel tank under the seat

I just picked this quad up a couple month ago and it's my first time opening things up. The original owner must have had the mice problems. I gotta blame it on him. There are way better things to eat in my garage.:grin
Good idea for the relay.

 

[QuadJunkie]

It's always good to have the extra time to do these type of projects.
Got the KFI part# 100545 winch mount and Superwinch LT2500 installed and
was cleaning around the wiring and found some bare wires. Not burned maybe mice?
I'm going to use liquid tape on these I think.

Also Looking to install the solenoid in the back storage box.

Got a question. Where and how do you guys attach the circuit breaker to the frame?

don't know about a circuit breaker ?, warn does not have this, and I only use warn. I mount my contactor switch in the trunk, as high as I can mount it.

So next time you need a Winch, buy the Superwinch. Hell I don't want to be the only one with this problem.:eek

 

[QuadJunkie]

Here's the relay. This thing is huge. Looks like it will be rusty someday soon.

 

[fishfiles]

QJ , you might want to look over the wiring harness for other spots were they had a bite to eat ---- they have eaten the rubber off the key when I let the key in the bike , and the boot of the spark plug wire

a good thing to do as a preventive maintenance thing would be to unplug every electrical connector on the bike and apply dielectric grease to them , especially since you have an ES and you can check the wiring as you go

 

[shadetree]

Here's the relay. This thing is huge. Looks like it will be rusty someday soon.

thats not a relay, that Is a fused link, and warn does not use that, least i've never seen them on any of the warns i've bought in the past ?.

 

[shadetree]

It's always good to have the extra time to do these type of projects.
Got the KFI part# 100545 winch mount and Superwinch LT2500 installed and
was cleaning around the wiring and found some bare wires. Not burned maybe mice?
I'm going to use liquid tape on these I think.

Also Looking to install the solenoid in the back storage box.

Got a question. Where and how do you guys attach the circuit breaker to the frame?

don't know about a circuit breaker ?, warn does not have this, and I only use warn. I mount my contactor switch in the trunk, as high as I can mount it.

So next time you need a Winch, buy the Superwinch. Hell I don't want to be the only one with this problem.:eek

lol, when I buy warns ?, I wont need to buy another winch ?, warn is one and done for me !..lol. I wont buy anything but a warn. bought a warn 10 years ago, ive used the crap out of it, have not replaced one thing on it to this day.

 

[Goober]

Here's the relay. This thing is huge. Looks like it will be rusty someday soon.

Wow that looks like a short waiting to happen— does it come with a cover?

 

[shadetree]

Here's the relay. This thing is huge. Looks like it will be rusty someday soon.

Wow that looks like a short waiting to happen– does it come with a cover?

lol, yeah, I was like..geeee..I wonder how long before it shorts out the leads ?..lol.

 

[Chalkymon]

Basic layout of my relay. Bolts passing through the rear face of the battery compartment. Straightforward but a little fiddly.

 

[shadetree]

my clean install of my contactor switch. I like my builds to be clean !..lol.

 

[Goober]

Basic layout of my relay. Bolts passing through the rear face of the battery compartment. Straightforward but a little fiddly.

Ok chalkster I see So your photo shows relative position of the contactor with fender removed. You had to mount it to the top side of the fender, in the drybox? That’s what I plan to do on my 300
Did you pass the cables thru a grommeted hole then? And did you waterproof the hole?

 

[shadetree]

Basic layout of my relay. Bolts passing through the rear face of the battery compartment. Straightforward but a little fiddly.

Ok chalkster I see So your photo shows relative position of the contactor with fender removed. You had to mount it to the top side of the fender, in the drybox? That’s what I plan to do on my 300
Did you pass the cables thru a grommeted hole then? And did you waterproof the hole?

his pic is not a trx300. if I remember right ?, his atv is a trx450es or manual shift ?..one of them !..lol.

 

[Macarena Man]

3500 Superwinch 'Terra" . . .

 

[Chalkymon]

Basic layout of my relay. Bolts passing through the rear face of the battery compartment. Straightforward but a little fiddly.

Ok chalkster I see So your photo shows relative position of the contactor with fender removed. You had to mount it to the top side of the fender, in the drybox? That’s what I plan to do on my 300
Did you pass the cables thru a grommeted hole then? And did you waterproof the hole?

Howdo mate. Just to confirm I didn't install the contactor inside the dry box! It's located between the forward side of the dry box & the rear side of the battery box as I had found the previously installed (WARN) item. The replacement unit fits in there very snug, better than the WARN item did, but as you can imagine there's very little space left between those compartments.

 

[Chalkymon]

Just above the cable seen behind the fuse box (with the infamous cover) are the x2 bolts locating the winch contactor to the other side of the panel (x1 bolt is shown in the image) Its a squeeze of a location but its well protected & quite secure.