Superwinch install on RTV500

[beretta96man]

So, here it is. I just finished and will take it out tomorrow and find somewhere to sink it in the white stuff to try it out. Looks like a really nice winch for the cost. It did require a couple mods but nothing that bad.

4500lbs Super winch terra 45 synthetic rope with KFI mount kit

1. Kit's mounting bolts were too short. To get ready, go to the store and get four 8mm x 30mm hex bolts, course thread I think (take the ones from the kit with you and get ones 1/4" longer so my advice doesn't screw you up). I got SS with all new washers/lock just for corrosion.
2. If you look closely at the plastic above the winch you can see I scribed an outline around it. The winch did fit behind it but the plastic was pushed out so I customized it with a dremel tool and a razor blade for a nice fit.
3. I have the factory grill guard and noticed that the front mounting bolts are in the way so 10 min with a 4" angle grinder cutting notches and I'm good to go. It's not on in this pic cuz I'm sending it out to get rhino lined next week.
4. Figured the best place to mount the solenoid was in front of the battery, looked nice and dry. I held it high so I could mount a second below as someday I want to put a winch in the rear.
5. Put the switch and socket for the remote left of the steering wheel. Used the replacement screws that came with the KFI mount kit for the switch mounting.
6. Went to the store and bought 1/4", 3/8", 1/2" and 3/4" flex loom to cover every wire. Looks great and protects the wires from rubbing.
7. Ran the winch wires up a new hole near the hood latch and down the passenger side floor channel and the switch wires down the driver's side.
8. **I spliced the two red wires for the switch ("key on") behind the dash but ran the long one with the rest back to the battery. I found a nice little factory "bullet" style connector that tested on with the key. It was red w/green stripe and blue taped to some flex loom below the fuse panel. I'm sure it was meant for some future add on and the best part was that I didn't have to tap into any dash wires. Just crimped a male bullet connector on and plugged it in.
9. Rope was a little tricky to get started in the spool. I ended up stripping the tape and winding new tape on tighter with a pointed end to thread it better.
10. LOVE the remote:thumbsup: Used it to feed to rope on. Otherwise that would have taken two people.

I took some time with this making it look as close to factory as I could Cuz I'm that **** (Hey I'm a trim carpenter, I can't help it :laughing That said it probably took me all of four hours to do but I ended up removing the battery, floor mat (only for the rhino lining), seat (easy) and drank some beer with my brother :drink:while contemplating where to mount things/drill holes. All the work itself is really easy, you just have to get to doing it.

Only thing I want to add is one of those rubber winch savers that sits behind the hook. I can see that the hook is going to scratch the Hawse which will eventually destroy my rope if I don't plan ahead here. Until I get that I'm going to leave the hook down/ loose.:thumbsup:

 

[General Lee]

Sweet. Thanks for the heads up on the bolt issues. I will get what I need before I plan to get mine installed. Won't be until after Christmas. Winch will be here but the mounting kit is delayed according to Amazon. What part of the front mounting bolts (Kit or brush guard) will you have to cut with the grinder?

Be sure to post some action pics when trying out the winch

 

[beretta96man]

Sweet. Thanks for the heads up on the bolt issues. I will get what I need before I plan to get mine installed. Won't be until after Christmas. Winch will be here but the mounting kit is delayed according to Amazon. What part of the front mounting bolts (Kit or brush guard) will you have to cut with the grinder?

Be sure to post some action pics when trying out the winch

It's the top of the Brush guard flat plate that mounts to the machine (above the 4 mounting holes). If you try turning the bolt heads so one side was parallel to the brush guard it might just work without grinding it as there is some play front to back on the winch mount and I think it may just work. I'm coating mine with bed liner so I needed it to be clear regardless because of the extra thickness and don't mind the bare metal for now, plus I figured making the cuts would allow for turning the winch bolts without removing the mounting plate first. If you grind yours you'll need to paint it so try to do it without first. Unless you do the coating My old wheeler racks and brush guards always rusted where scratched so I'm coating ever surface that might get scratched on this machine before the rust starts.:thumbsup:

If I were you I'd mount the winch to the mounting plate on a bench then slide it in and before you mount it to the machine lift it up and slide the brush guard on and play with it to see what you want to do. Regardless, the brush guard needs to be back on before you do the final mount or you won't be able to get the guard back on. And if you wish to cut the plastic (I would recommend it) do it before the brush guard.

 

[DIXIEDOG]

Looks like that'll work pretty well. The factory winch sits entirely in the factory cubby hole for the winch, I'm surprised the Superwinch bolt pattern didn't line up with those 4 holes.

 

[DIXIEDOG]

This is how the factory winch sits in

 

[beretta96man]

Looks like that'll work pretty well. The factory winch sits entirely in the factory cubby hole for the winch, I'm surprised the Superwinch bolt pattern didn't line up with those 4 holes.

I bought the KFI mount plate because it said it would work with the Super winch as it is longer and taller than the RT25. It's holes are more forward and the winch cubby does slightly taper in towards the back so it gets smaller in there. I could have got it back farther but would have had to drill new holes, I'm fine with it.

 

[beretta96man]

Well, I sure took me a while to get this thing stuck somewhere. I'm impressed, even if I couldn't go forward if I backed up and took a run at it I always got out. When I finally did get stuck I shouted "alright, we're stuck!" to which my little boy replied "we wanted to get stuck daddy?":laughing: some day he'll understand.

winch worked great, little stiffer to free spool out then my warn A2000 was but I love the rope over twisting metal cable. More stretch though but it pulled it out in N. Really low gearing.

Does the hydro in neutral still have pressure on the drive train? I felt like I was winching against some pressure in N. With it in drive the winch was barely needed as an assist, I was just playing with the winch.

 

[beretta96man]

Here I found out first hand how mislead I was about the 4wd and lack of locking front end

Set the parking brake and Got my brother on the Big Bear in N out of a small ditch with ease

Sorry about the pics, on my computer they are right side up but here they are upside down and I can't rotate them

**ALL FIXED, found a way to rotate of this site's uploading.

 

[two_bit_score]

Very nice. Thanks for the pics.

 

[DIXIEDOG]

Does the hydro in neutral still have pressure on the drive train?

It shouldn't, to check it out you need to jack up the rear end and start the buggy in neutral. The tires should not move, if they do an adjustment for creep needs to be made. If you have to make the adjustment I can look the instructions up and PM them over.:thumbsup:

 

[beretta96man]

It shouldn't, to check it out you need to jack up the rear end and start the buggy in neutral. The tires should not move, if they do an adjustment for creep needs to be made. If you have to make the adjustment I can look the instructions up and PM them over.:thumbsup:

After x-mas I'll have it up in the air when I put the tracks on. If I need to I'll take you up on that:drink:

Also my all knowledgeable dealer touted that I could leave it in gear on a hill and it wouldn't move. True on the flat but it rolled back in front of the garage when I got out to open the door.

The Shifting is really bugging me. Seems like 80% of the time I can't get it in gear. Why is that? If I move the machine OR if I slightly give some gas it will pop in gear that I want but seems like the tranny is still under load. Is there a better way? On the dash instructions say not to force and to use the throttle but too much and it grinds, no good.........

 

[DIXIEDOG]

After x-mas I'll have it up in the air when I put the tracks on. If I need to I'll take you up on that:drink:

Also my all knowledgeable dealer touted that I could leave it in gear on a hill and it wouldn't move. True on the flat but it rolled back in front of the garage when I got out to open the door.

The Shifting is really bugging me. Seems like 80% of the time I can't get it in gear. Why is that? If I move the machine OR if I slightly give some gas it will pop in gear that I want but seems like the tranny is still under load. Is there a better way? On the dash instructions say not to force and to use the throttle but too much and it grinds, no good.........

Are you stepping right down on the brake? I had an issue with mine at one time but what had happened is I was just letting off the go pedal and letting the buggy stop, I didn't notice but I had basically stopped using my brake the buggy was just sitting there. I started pressing the brake down fully before shifting and haven't had any issues since.

 

[beretta96man]

Are you stepping right down on the brake?

Yep, but maybe I need to push harder. I only have 4hrs on it now so obviously more time is needed to play-I mean work with it

 

[Chad450r]

Just curious do you no what that winch is rated at for recommended power? I was told by Warn Tech Dept that the whole reason Kubota uses the 2.5 and not rt40 is that the battery is not enough cca and thus causes the winch motor to prematurely fail. So I would need to add a bigger cca battery in my rtv 900.

 

[nickel plate]

Just curious do you no what that winch is rated at for recommended power? I was told by Warn Tech Dept that the whole reason Kubota uses the 2.5 and not rt40 is that the battery is not enough cca and thus causes the winch motor to prematurely fail. So I would need to add a bigger cca battery in my rtv 900.

I checked the stock battery specs on my Kawasaki Mule Trans diesel before I made the install and it would support the Warn RT40. Otherwise, yes, you can change out the battery and the battery box/bracket to run a heavier duty winch.

 

[General Lee]

Kit's mounting bolts were too short. To get ready, go to the store and get four 8mm x 30mm hex bolts, course thread I think (take the ones from the kit with you and get ones 1/4" longer so my advice doesn't screw you up). I got SS with all new washers/lock just for corrosion.
Used the replacement screws that came with the KFI mount kit for the switch mounting.

When you say "Kit" are you referring to the Superwinch kit itself, not the KFI mounting bracket kit? I started tearing into things and found the 4 bolts that mount the hawse bracket and the winch its self to the mounting plate are to short. These are the ones your referring to right?

Also, what bolts did you use to mount the blue anodized hawse (fair lead) to the hawse bracket? I'm not finding any bolts supplied to work. Apparently they call for a square head bolt but I don't have any in the kit. I also don't think my KFI kit came with a mini rocker kit. The only thing that is working for me is the bolts for the replacement stock mounting plate.

I know you gave a heads up on the bolt issue, I was just piddling with everything getting a game plan. No stores open on Christmas so I'll have to wait until tomorrow to get bolts.

 

[Blitz51]

Great pics. Thanks for sharing.

 

[beretta96man]

When you say "Kit" are you referring to the Superwinch kit itself, not the KFI mounting bracket kit? I started tearing into things and found the 4 bolts that mount the hawse bracket and the winch its self to the mounting plate are to short. These are the ones your referring to right?

Also, what bolts did you use to mount the blue anodized hawse (fair lead) to the hawse bracket? I'm not finding any bolts supplied to work. Apparently they call for a square head bolt but I don't have any in the kit. I also don't think my KFI kit came with a mini rocker kit. The only thing that is working for me is the bolts for the replacement stock mounting plate.

I know you gave a heads up on the bolt issue, I was just piddling with everything getting a game plan. No stores open on Christmas so I'll have to wait until tomorrow to get bolts.

Sorry, I've been gone for the holidays. Looks like you figured it out though. Too bad the first one was bad. Let me know how this one works. Mine's been good so far but only used it twice. I want another for the rear but will wait until I make sure there aren't any problems.

Reading your thread:
I put my rope on from the bottom like the instructions said, looks like yours does.

I pulled my 500 out of the snow in neutral up a slight incline to the driveway and while geared slow it did the job just fine. Let me know how yours works!

 

[General Lee]

Sorry, I've been gone for the holidays. Looks like you figured it out though. Too bad the first one was bad. Let me know how this one works. Mine's been good so far but only used it twice. I want another for the rear but will wait until I make sure there aren't any problems.

Reading your thread:
I put my rope on from the bottom like the instructions said, looks like yours does.

I pulled my 500 out of the snow in neutral up a slight incline to the driveway and while geared slow it did the job just fine. Let me know how yours works!

Yea I figured it out. I gotta say it was a royal pain in the _$$. Now that its all installed, looking back it wasn't so bad but during..... I didn't have to notch the brush guard. Takes a bit of persuasion but it worked. The bolts for the hawse....... I guess I used the right ones. The carriage bolts supplied didn't work because the nuts mated for them wouldn't fit in the hawse's holes. Another set bolts supplied worked. Thankfully I found a socket that would fit in the hole. I didn't want exposed bolts or nuts, fearing the rope would get torn on them.

I did run the wires through the channels on the floor board. A couple wires I needed to fish with a coat hanger. After ruining a few of the plastic plugs that hold the rubber mat on, I decided to fish them through.

I did install the rope per the instructions, but when I had a defective winch, I started questioning myself if I did something wrong. That's why I wanted to make sure I was winding the rope right.

Amazon was great. 24 hours later I had a new winch. Since all the hard work was done, I just had to swap winches, no wiring. Today I hooked to a tree and pulled the machine in Neutral with the E-brake on. The winch skidded the machine across the ground no problem.

On paper, the winch seems to be good quality. They advertise they supply it with the Dynaneema fiber rope which is top of the line apparently, although only 1/4 inch in diameter. Do you happen to know the CCA of the battery on the 500? Just curious if the battery is sufficient for the winch in the long run. When I had the battery out, there was no CCA posted on it.

 

[beretta96man]

Do you happen to know the CCA of the battery on the 500? Just curious if the battery is sufficient for the winch in the long run. When I had the battery out, there was no CCA posted on it.

Don't know off hand, Dixie has a manual that might call out the specs. I had my batt out too and didn't see anything on it. The battery on the 500 is, by comparison, WAY larger than any atv's battery I've run before with 2500lbs winches and no problems. I'm going to run mine until it gives me reason to go larger. So far no problems in shortage of power.

You pulled it with the e-brake on? Now that's impressive:thumbsup: