The winch's solenoid is its power switch and main safety device. When electricity is sent to the solenoid upon activation of the power switch, a magnetic field causes the circuit to the winch to be completed and power to be sent to the device for operation. The solenoid protects the winch from being used without a key in the ignition. Wiring the solenoid to the winch and the switch is the final step in the installation process.
I started mounting my new winch this after noon (superwinch terra 25) on my 2012 400. I ran into questions were I was to mount the solenoid. It said near the battery, in dry and clean area, away from frame tubes. Mount the winch to the front of the ATV using a mounting plate designed for both your ATV and the winch you purchased. Hook up the wires to the winch. On the Suzuki Vinson, the 6 gauge wires are already there for a winch so just hook them up according to the winch installation instructions.
Step 1
Run the positive and negative motor wires from the winch to the solenoid. Fasten these wires to the correctly labeled terminals on the solenoid by backing off the terminal nuts and securing the ring connectors over the terminal bolts. Tighten the terminal nuts back down.
Step 2
Connect the positive and negative battery wires to the solenoid's terminals marked for the battery. Pay attention to the proper polarity. The red (+) wire goes to the positive terminal and the black (-) wire goes to the negative terminal.
Step 3
Run the solenoid's battery wires to the vehicle's battery and fasten them to the correct polarity terminals.
Fasten the two wires from the winch's on/off switch or remote to the correctly labeled terminals on the solenoid. These wires are typically color coded to match the solenoid terminals. If they are not, you must trace them back to their source to determine their polarity. Then make the connections to the solenoid based on this information.
Tip
- Test your winch's operation prior to heading out on the trail.
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The winch has two movements: 'in' and 'out.' A direct wire links the winch solenoid to the battery. Routine maintenance checks can extend the longevity of the winch simply by reconnecting cable and wiring connections. The most recognizable sound a working winch makes is a clunk when it is given power. The power passing through the solenoid winch is 12 volts. During use, the two smaller lug studs of the winch hold 12 volts each; the other lug studs have continuous energy in the 12-volt range. Electric shock from touching the lug studs is painful.
Step 1
Check the cable connections from the winch solenoid to the battery. If the cable terminals look corroded, clean them with a wire brush. If the cables look frayed, replace them with new ones.
Step 2
Unscrew the solenoid cover after you disconnect the positive (red) winch cable from the battery. Make sure all the connections in the solenoid are secure; if you hear a clicking noise when you turn the winch, a wire might be loose.
Step 3
Touch a voltmeter to the large studs on the solenoid with the winch turned off. The two large studs are on the winch side of the solenoid. The voltmeter will read 12 volts if the solenoid is working.
Step 4
Test the two small studs on the control side of the solenoid that is opposite of the winch side with the winch off. If the voltmeter reads 12 volts, then the solenoid is not working properly.
Step 5
Conduct another voltmeter test on the large studs with the winch turned on. There should be no OHM reading.
Measure the OHM reading of the two small studs with the voltmeter when the winch is on. If there is no reading on the voltmeter, then the solenoid isn't working properly. The two small studs are energized with the winch activated.
Tip
- Don't ever just start replacing parts on a vehicle. Always take the time to investigate the cause of a bad connection.
Warning
- Disconnect the battery before you remove the solenoid cover plate. The battery has enough power to give a significant electric shock.
Items you will need
- Wire brush
- Screwdriver set
- Voltmeter
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