Installation Guide

Fig. 4 - Proper Terminal Tightening
WARNING
!
Ensure that the wiring harness does not interfere or come in con-
tact with any hot or moving engine, suspension, steering, braking
or exhaust parts.
TOGGLE SWITCH INSTALLATION
CAUTION
!
When attaching wires to the motor or solenoid terminals, hold the
inner nut with a wrench while tightening the outer nut with a
second wrench. Do not allow the terminals to rotate in their housings. Rotation may cause
internal wire breakage or part misalignment ( Fig 4).
Step ( 1 )
Check to ensure that the vehicle ground and positive leads from the battery are
disconnected before performing any electrical work.
DANGER
!
DO NOT ATTEMPT TO INSTALL WIRING WHEN THE BATTERY IS
explosive gases. Wear eye protection during installation and remove all metal
jewelry. Do not lean over battery while making connections.
Step ( 2 )
Route the wiring harness, attaching the harness to hard points on the vehicle with
cable ties.
Step ( 3 )
Using the supplied clamps, bracket and hardware, mount switch in a convenient
location. See Fig. 5.
Fig. 5
Step ( 4 )
It is recommended that the switch be installed on the left handlebar.
Step ( 5 )
Once the switch is mounted, route the jacketed green and black leads back to where
the solenoid is mounted. Splice the red lead into wire that energizes with ignition
WIRING INSTALLATION
On the top of the solenoid, connect the RED 6 ga. wire to the terminal C.
Route the opposite end of the RED 6 ga. wire to the circuit breaker and connect the RED
6 ga. wire to the unmarked side of the circuit breaker. (see Fig. 6)
Step ( 3 )
On the top of the solenoid, connect the BLACK 6 ga. wire to terminal
D. (see Fig. 3)
On the solenoid, check that the short BLACK jumper wire lead, is installed from the
solenoid’s center
E, to the solenoid’s terminal D. (see Fig. 3).
Attach the GREEN wire from the rocker switch to the outer left spade, F connector, of
the solenoid. Attach the GREEN wire from the optional socket assembly to the same
outer left spade connector,
F. note; the solenoid top side up (see Fig. 6 and 3)
Attach the BLACK wire from the rocker switch to the outer right spade connector
G
on the solenoid. Attach the BLACK wire from the optional socket assembly to the
same outer right spade connector
G. note; the solenoid top side up (see Fig. 6 and 3)
Step ( 7 )
Connect the RED WIRE, from the rocker switch and optionally from the socket assem-
bly to your ATV’s Ignition Switch key controlled wire. This wire must only have power
when the key is in the on position. A fuse protected key controlled wire is prefered.
Fuse should be rated for at least 4 amps. Cover-wind the connection with muti-layers
of CE approved electrical insulation tape, (see Fig. 6).
Note: When routing the wires, the appropriate terminals should be located near the
battery, switch mounting point, and winch. Your installation requirements will vary
depending upon your vehicle and winch. Make sure wires are long enough to reach
the battery, switch mounting point and winch.
CAUTION
!
ALWAYS USE THE SWITCH MOUNTING BRACKET, SCREWS, AND
LOCK NUTS PROVIDED. Screw lengths are sized for correct
penetration into switch box. Excess penetration may result in short circuits that could
lead to wire over heating.
Route the opposite end of the BLACK wire from, solenoid terminal
D, and connect to
the “-” negative terminal on the battery. (see Fig. 6)
Connect the short RED 6 ga. wire to the end of the circuit breaker, marked “ “positive .
Connect the other end of this RED wire to the “+” positive battery terminal. (see Fig. 6)
Step ( 9 )
Step ( 8 )
Step ( 10 )
Check that all wiring is clear of sharp edges and pinch points. Check that all wiring is
tie wraps and electrical insulation tape.
7
Step ( 1 )
Connect the YELLOW 6 ga. wire to the #1 “+” positive terminal on the motor and connect
the BLUE 6 ga. wire to #2 “-” negative terminal to the motor. (see Fig. 6)
Route the opposite ends of the YELLOW 6 ga. and the BLUE 6 ga. wires back to the solenoid.
On the top of the solenoid, connect the YELLOW 6 ga. wire to terminal
A “+” positive.
Also, on top of the solenoid connect the BLUE 6 ga. wire to terminal B “-” negative. (see Fig. 3)
6
Step ( 2 )
Step ( 4 )
Step ( 5 )
Step ( 6 )