Installation Instructions,

Operator's Manual and

Replacement Parts List for
the
A2500
ATV WINCH
 SAFETY PRECAUTIONS

MOVING PART HAZARD

TO PREVENT SERIOUS INJURY AND PROPERTY DAMAGE:

• Do not operate or install winch without reading and

understanding the operators manual.

• Keep hands clear of wire rope, hook, and fairlead

opening during operation and when spooling.

• Stand clear of wire rope and load during operation.

• Keep others away.

• Always inspect winch installation and wire rope

condition before operating winch.

• Do not exceed winch rated capacity.

• Never touch wire rope or hook while in tension.

PAGE 2
 APPLICATION INFORMATION

TO PREVENT SERIOUS INJURY:

• Do not use as a hoist.
• Do not use to move persons.

TO AVOID INJURY AND PROPERTY DAMAGE:

• Do not use winch to secure a load during transport.
• Do not submerge in water.
• Do not use to tow other vehicles.

Maximum single line pulling capacity : 2500 lb. (1100 kg).

Intermittent duty rating.
12 Volts DC.
Use only 3/16" (4.8 mm) 7 x 19 aircraft wire rope.

PAGE 3
 INSTALLATION INSTRUCTIONS
STEP ONE - SAFETY FIRST
When installing your ATV winch system, read and follow all mounting and
safety instructions. Always use caution when working with electricity and remember
to verify that no exposed electrical connections exist before energizing your winch
circuit.

PAGE 4
STEP TWO - WINCH MOUNTING
ATV winch mounting kits are available from your Warn Dealer to satisfy nearly
all ATV applications. For information on available kits, contact your Warn product
dealer.

To secure the winch, always use:

A flat, secure mounting location at least 3/16 in. (4.8 mm) thick.
5/16 in. (8mm) Lockwasher.
Must use the 5/16-18 x 1 in. , grade 5 hex head capscrews supplied.
Torque mounting bolts to 12 ft-lbs (1.7 kg-m).

STEP THREE - REMOTE SOCKET INSTALLATION

! WARNING

TO PREVENT SERIOUS INJURY OR DEATH FROM EXPLOSION :

• Do not drill into gas tank.
• Verify the area is clear behind the mounting location before drilling.
After determining the mounting location for the remote socket plug drill three
holes and install (see page 6)

PAGE 5
 ! WARNING

TO PREVENT SERIOUS INJURY OR DEATH FROM ELECTRICAL FIRE:

• Do not route electrical cables across sharp edges.
• Do not route electrical cables through or near moving parts.
• Point keyway of the remote control socket down.

10-24 hex nut

& lockwasher

Keyway must
point down

10-24 X 3/4in.
hex head capscrew
1/4in. (6.4mm) DIA. 2 plcs.

7/8in. (22.2mm)

Not to scale.
7/8in. (22.2mm) DIA. Do not use as a
template
1 3/4in. (44.5mm)

PAGE 6
 Once the remote socket is mounted, run the two bullet terminals wires up to
where the contactor pack will be mounted. Splice the end of the red 20ga wire to a
key controlled electrical wire of the ATV. Using a test light, locate a suitable wire
from the ATV key switch. The wire should only have power when the key is in the
“ON” position.

OFF

ON

Test Light Key

To Motor Terminal #2 splice

(blue)
96 in (.4mm) black wire

To Battery ( - )
(black)
36in (.92mm)
black wire red wire

To Battery ( + )
(red)
36in (.92mm)
red wire

To Motor Terminal #1
(Yellow)
96 in (.4mm) black wire

PAGE 7
STEP FOUR - SOLENOID INSTALLATION
The solenoid is a primary safety feature in your winch system. It disconnects
your winch from its power source when the ATV is not in use. Carefully follow the
instructions for installation. The solenoid must be correctly installed to work
properly.

It is recommended, If possible, that the solenoid be mounted in the location

shown on page 4. This may require the removal of the storage box from the ATV
frame. Once the storage box is removed use the solenoid as a template to drill the
mounting holes on top of the storage box.

Caution - All wires must be attached to the solenoid before mounting the storage
box back to the ATV frame. Place the supplied terminal boots on wires
before securing to the solenoid.

Attach the male and female bullet terminals of the green and black remote
socket wires to the male and female bullet terminals of the solenoid as
shown on page 7.

Attach the 36in (.92m), 6ga red wire to the positive solenoid post (bottom
left terminal) and battery (shrink wrapped end to battery). Attach the 36in
(.92m), 6ga black wire to the negative solenoid post (top right terminal) and
battery.

Attach the two 96in (2.4m) 6ga wire marked #1, yellow and #2, blue to the
blue and yellow solenoid posts (see page 7) and to motor terminals 1,
yellow and 2, blue.

Attach the solenoid to the storage box and reassemble the storage box to
the ATV frame. Assure that cables do not cross sharp edges, moving parts,
or contact items that may become hot.

PAGE 8
STEP FIVE - REMOTE CONTROL INSTALLATION
It is recommended that the remote control holder be installed on the left
handle bar. A piece of electrical tape around the handle bar will help
secure the holder.

Do not tighten over hoses or any cables.

Place the remote into the holder and attach the strap.

When the winch is not in use it is recommend that the remote control be
unplugged and placed in the storage box.

1/4 20 X 1 1/2 in.

capscrew

1/4 - 20 locknut

STEP SIX - SYSTEM CHECK

Before using the winch, verify the following:
Wiring to all components is correct. All loose wires are tie wrapped tight.

There are no exposed wiring or terminals, cover any existing exposures

with insulator plate, terminal boots, heat shrink tubing or electricians tape.

The solenoid is properly grounded.

Turn ATV key switch to ON position. Check winch for proper operation.

PAGE 9
 IN OUT

! CAUTION
KNOW YOUR WINCH: Take time to fully understand
your winch and the winching operation.

OPERATING INSTRUCTIONS
CLUTCH OPERATION

! WARNING
TO PREVENT SERIOUS INJURY OR PROPERTY DAMAGE:
z Do not disengage clutch if winch is under load or
wire rope is in tension.

When the clutch is engaged the gear train is coupled to the wire rope drum and
power may be transferred from the winch motor. When the clutch is in free spool the
gear train and wire rope drum are uncoupled allowing the drum to rotate freely. The
clutch knob, located on the winch housing opposite the motor, controls the clutch
position. To prevent damage, always fully engage or fully disengage the clutch
knob.

PAGE 10
 Engaged Freespool

Engage fully
until clutch
knob “clicks”
into place

OVERLOADING/OVERHEATING
This winch is rated for intermittent duty. It should not be operated with the motor
slowed down to a low RPM. When the motor approaches stall speed, a very rapid
heat build-up occurs which may cause motor damage. To judge safe running time,
stop winching and lay your hand on the motor. If the temperature is uncomfortable,
shut down and cool the motor. This can be used as an opportunity to recharge the
battery. Double line rigging will reduce the amperage draw from the motor allowing
longer continual use (see rigging section).

BATTERY RECOMMENDATIONS
A fully charged battery and good connections are essential to the proper
operation of your winch. The minimum requirements for a 12 volt DC battery is 12
AMP hours.

MAINTENANCE
No lubrication is required for the life of the winch.
Check battery cables at 90 day intervals to be certain that they are clean
and tight at all connections.
Inspect the wire rope before and after each winching operation. Replace
when damaged.

PAGE 11
 TO AVOID INJURY AND PROPERTY DAMAGE:

• Wear heavy leather gloves when handling wire rope.

• Never winch with less than 5 wraps of wire rope around

drum.

SPOOLING OUT
Freespooling is generally the quickest and easiest way to spool out wire rope.
Before freespooling wire rope out from the winch, power out enough rope to
remove any tension the wire rope may be under before disengaging the clutch.
Now freespool by manually spooling out enough wire rope for the winching
operation.

STRETCHING THE WIRE ROPE

The life of a wire rope is directly related to the care and use it receives. During
its first use, a new wire rope must be spooled onto its drum under a load of at
least 500 lb. (227kg). Spool out the wire rope length leaving 5 wraps on the
drum, then power in the wire rope under a load of 500 lb. (227kg) or more. This
will stretch new wire rope and create a good wire wrap around the drum. Failure
to do so may result in the outer wire wraps drawing into the inner wraps, binding,
and damaging the wire rope. Wire rope damage is specifically excluded from
warranty.

PAGE 12
 TO PREVENT SERIOUS INJURY:

• Keep hands clear of wire rope, hook, and fairlead

opening during operation.

• Always use the hook strap to hold hook when

spooling.

SPOOLING IN UNDER LOAD

The wire rope must always spool onto the drum as indicated by the drum
rotation decal on the winch.

Power in the wire rope evenly and tightly on the drum. This prevents the
outer wire wraps from drawing into the inner wraps, binding and damaging
the wire rope.

Avoid shock loads when spooling, by using the control switch intermittently
to take up wire rope slack. Shock loads can momentarily far exceed the
winch and wire rope ratings.

When powering in wire rope during side pull operations the wire rope will
stack up at one end of the drum. Eventually this stack will become large
enough to cause serious damage to the winch. To prevent damage, line up
pulls as straight ahead as possible and stop winching if the wire rope
comes close to the tie rods or mounting plate. To correct an uneven stack,
spool out that section of the rope and reposition it to the opposite end of the
drum which will free up space for continued winching.

PAGE 13
SPOOLING IN UNDER NO LOAD
Assisted: Have your assistant hold the hook with a cord or rag putting as
much constant tension on the wire rope as possible. While keeping
tension, the assistant should walk toward the winch while you operate the
control switch spooling in the wire rope. Release the switch when the hook
is a minimum of 4 ft (1.2m) from the fairlead opening. Spool in the
remainder for storage.
Unassisted: Arrange the wire rope to be spooled so it will not kink or
tangle when spooled. Be sure any wire rope on the drum is tightly and
evenly layered. Spool enough wire rope to complete the next full layer on
the drum. Tighten and straighten the layer. Repeat process until the hook is
a minimum of 4ft (1.2m) from the fairlead. Spool in the remainder for
storage.

SPOOLING REMAINDER FOR STORAGE

Keep hands clear of wire rope, hook, and fairlead opening. Always use a rag
or cord to hold hook when spooling under no load. Carefully power in the
remaining wire rope, jogging the control switch to take up the last of the slack.
Secure the hook to a suitable anchor point near the winch. Be careful not to over
tighten or damage may occur to the wire rope or anchor point.

TO PREVENT SERIOUS INJURY:

• Stand clear of wire rope and load during operation.

• Be certian the anchor will withstand the load.

• Always use a choker chain, wire choker rope,

or tree trunk protector on the anchor.

• Take your time, sloppy rigging causes accidents.

PAGE 14
RIGGING
Always spool out as much wire rope as possible when preparing rigging.
Pick an anchor as far away as practical. This provides the winch with its greatest
pulling power.

Rigging a double line with a snatch block will reduce the load on the winch to
half without significant loss of spooling speed.

Natural anchors such as trees, stumps and rocks are the handiest when
available. Attach the choker chain, wire choker rope or tree trunk protector on
the anchor as low as possible to avoid pulling the anchor down. If several
possible anchors are available but they are not strong enough individually, it
may be practical to attach a wire or chain choker around several anchors to
form a strong collective anchor point.

Pulling Power Wire Rope Layer

2500 lb. (1134kg) 1st layer closest to drum core
2200 lb. (998kg) 2nd layer
1930 lb. (875kg) 3rd layer
1700 lb. (771kg) 4th layer

Some of the most commonly used riggings are shown on page 16.

PAGE 15
PAGE 16
 Warn Winch
One Year Limited Warranty
(VALID ONLY ON WINCHES SOLD IN NORTH AMERICA)

Warn Industries, Inc. ("Warn") warrants parts and labor directly to the first purchaser of each Warn winch
against defects in material and workmanship appearing under normal use and service for a period of one
(1) year from the date of purchase. To obtain any warranty coverage hereunder, it is absolutely necessary
to fill out completely and mail in the registration card within ninety (90) days of the date of purchase. If you
discover a covered defect, Warn will, at its option, repair, replace or refund the purchase price of this winch
or winch parts at no charge to you, provided you return it during the applicable warranty period,
transportation charges prepaid, to Warn Industries' Service Department or Factory Authorized Servicing
Distributor. (You can obtain additional information from Warn directly at the address printed below). Please
attach your name, address, telephone number, a description of the problem and a copy of the bill of sale
bearing the appropriate Warn serial numbers as proof of original retail purchase, to each product returned
for warranty service. To obtain any warranty coverage, it is absolutely necessary that you present proof of
purchase acceptable to Warn, such as a copy of the purchase receipt. Returning a fully completed
registration card to Warn within ninety (90) days of the date of purchase is a condition precedent to warranty
coverage.

This warranty applies only to winches manufactured by Warn, which can be identified by the "Warn"
trademark, tradename or logo affixed to them. Warn does not warrant any products that are not Warn
products. This warranty does not apply if the product has been damaged by accident, abuse, misuse,
collision, overloading, exhaust or misapplication, or has been improperly installed, has been improperly
used, has been improperly serviced, or has been modified without the written permission of Warn. This
warranty does not apply if any Warn serial number has been removed or defaced. The finish and wire rope
on the product are excluded form this warranty. In addition, commercial or industrial use or application, or
any hoisting application of the product without prior written approval of Warn voids the entire warranty.

Except as expressly stated herein, there are no warranties, express or implied, including any implied
warranties of merchantability and fitness for a particular purpose. Any implied warranties of merchantability
and fitness for a particular purpose, which by law may not be excluded, is limited in duration to one (1) year
from the date of the original retail purchase of this product.

The warranty and the remedies set forth above are exclusive and in lieu of all others, oral or written,
express or implied. No Warn dealer, agent or employee is authorized to make any modification, extension
or addition to this warranty.

In no event is Warn responsible for special, incidental or consequential damages resulting from any breach
of warranty, or under any other legal theory, including, but not limited to lost profits, down time, goodwill,
damage to or replacement of equipment and property, loss of use of this product or of any associated
equipment, or cost of substituted products.

Some States do not allow the exclusion or limitation of incidental or consequential damages, or limitation on
how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty
gives you specific legal rights, and you may have other rights which vary from state to state.

Warranty inquires should be directed to: WARN INDUSTRIES, INC.

Customer Service Department
12900 SE Capps Road
Clackamas, Oregon 97015-8903

PAGE 17
 WARN A2500 ATV WINCH
REPLACEMENT PARTS LIST
ORDERING INFORMATION: Parts may be obtained through your local dealer or distributor.

ITEM QTY NUMBER DESCRIPTION

1 1 36030 Endhousing, Clutch assy (includes items 3 & 4)
1 1 36053 Endhousing, No Clutch
2 4 7953 Square Nut
3 1 21872 Cam Follower
4 1 21895 Thrust Plate
5 1 21292 Sun Gear, Stage 2
6 1 21329 Carrier Assy., Stage 2
7 1 21330 Carrier Assy., Stage 3
8 2 21665 Drum Support
9 2 21296 Drum Bushing
9 2 21597 Drum Support with Bushing
10 2 25257 Cable Protector
11 1 60078 Drum Assy (no wire rope)
11 1 39315 Drum Assy
12 1 60076 Terminal Kit, 3/16" Wire Rope
13 2 21268 Tie Rod
14 1 34797 Drive Shaft
14 1 30468 Drive Shaft, No Clutch
15 1 21319 Thrust Washer
16 1 21883 Clutch Return Spring
17 1 21320 Carrier Assy., Stage 1
18 1 21290 Sun Gear, Stage 1
19 1 36054 Endhousing, Motor assy (includes part # 35033 & 21316)
20 4 8956 Socket Head Capscrew 1/4-20 X 1/2
21 4 1936 Socket Head Capscrew 1/4-20 X 5/8
22 1 21594 Armature, 12 VDC Motor
22 1 22572 Armature, 24 VDC Motor
23 1 36031 Motor, 12 VDC
23 1 36032 Motor, 24 VDC
24 1 31928 Cap assy, 12 & 24 VDC Motor
25 2 34786 Cable assy, 6ga, black, 96in
26 6 2090 Boot, Electric terminal
27 4 1321 ¼ washer
28 1 62259 Cable assy, 6ga, black, 36in
29 1 62263 Cable assy, 6ga, red, 36in
30 4 1319 ¼-20 X 3/4 Hex Capscrew
31 4 1322 ¼-20 Hex Nut
32 1 62135 Contactor, 12 VDC
33 1 37677 Remote control, 6ft
34 1 21842 Splice, 20 GA
35 1 62258 Remote control socket
36 2 2317 3/8-16 fin hex nut
37 2 1829 3/8 lockwasher
38 1 28929 Roller fairlead
39 2 2228 3/8-16 hex head capscrew
41 1 35296 Hook, 5/16 Clevis Slip
42 4 1402 5/16 Lockwasher
43 4 21331 5/16-18 Hex Head Capscrew
44 1 21666 Fairlead, Plate Mounting
45 1 37676 Handle bar mount
46 1 37674 Rubber Strap
47 1 2514 1/4-20 X 1.5 Hex Head Capscrew
48 1 6725 1/4in Locknut
49 1 38293 Strap, Hook
PARTS BREAKDOWN

PAGE 19
PAGE 20
PAGE 21
PAGE 22
 WARN FACTORY AUTHORIZED SERVICE CENTERS
NORTHWEST REGION
WARN INDUSTRIES, INC.
12900 SE Capps Rd.
Clackamas, OR 97015
503-722-1200
503-732-3000 (fax)
800-543-9276
TC'S Off Road Center
730 North Central
Kent, WA 98032
206-852-2720
800-962-1463
Six States Distribution Inc.
2138 Century Way
Boise, ID 83709
208-377-9393
800-632-2006 (in state)
800-625-3702 (out of state)
ROCKY MT. REGION
Fort Collins 4x4 Performance
1101 N. College Ave.
Ft. Collins, CO 80524
970-482-5500
Predator 4 Wheel Drive
2340 Montebello Dr.
Colorado Springs, CO 80920
719-528-5790
Six States Distribution Inc.
247 West 1700 South
Salt Lake City, UT 84115
801-488-4666
800-453-5703 (out of state)
801-488-4676
SOUTHWEST REGION
DSI Dist. Inc.
6025 Corridor Parkway
Schertz, TX 78154
210-651-2000
800-374-8028
Four Wheeler Supply
3530 East Washington St.
Phoenix, AZ 85034
602-273-7195
800-352-8602
SOUTHEAST REGION MID WEST REGION
Clemson 4WD Center 4 WD Center of Minnesota
Hwy. 123 South 5711 West 36th St.
Clemson, SC 29633 St. Louis Park, MN 55416
864-882-0277 612-927-8811
800-257-4294 800-622-0781 (in state)
800-328-4445 (out of state)
Reliable Equipment, Inc. 612-927-4500 (fax)
7779 Dixie Hwy.
Louisville, KY 40258 NORTHEAST REGION
502-935-5501
800-626-6532 Hoaks 4 WD Center
815 Hei!am St.
Rowland Powertrain Wrightville, PA 17368
2265 W. Beaver St. 717-252-3602
Jacksonville, FL 32236 800-827-1341
904-354-5691 717-252-2296 (fax)
800-741-0603
CANADA
SOUTH REGION
AIR ELECTRIC SERVICES
Ivy R. Redding, Inc. 6739 76th Ave.
l-20 Calhoun exit 103 Edmonton, Alberta T6B OA9
Calhoun, LA 71225 780-465-0906
318-644-2883 780-469-1646 (fax)
800-256-8656
318 644-2684 (fax) Drive Products, Inc.
1661 Trinity Drive
Dealers Truck Eguip. Co. Mississauga, Ontario
6601 l-30 L5T 1K4
Little Rock, AR 72209 905-565-5800
501-568-9000 905-564-5799 (fax)
800-568-9006
Twin Equipment Ottawa
Big Ten Tire 1377 Triole St.
712 S. State St. Ottawa, Ontario K1B 4T4
Jackson, MS 39201 613-745-7095
601-354-4333
601-748-6806 (fax) Husky Equipment
1136 Boundary Road
Weathers Auto Supply Vancover, British Colum.
1219 S. Gloster V5K 4T5
Tupelo, MS 38801 604-294-4424
601 842-5577
800-647-8142 McCoy Brothers
5255 128th Ave.
WESTERN REGION Edmonton, Alberta T5A 5C2
780-413-6655
Garvin Industries, Inc. 780-413-6657 (fax)
316 Miller Ave.
El Cajon, CA 92020
619-440-7415
PN 38136 REV. C0