Warn 2.5ci problems

[cdover73]

I have a Warn 2.5ci on a 2003 Kawasaki Prairie 360. The other day I was letting a friend ride his young son on the bike around my yard. When they pulled back up I heard a horrible grinding sound and realized the kid was holding onto the handle bars and had his hands on the "in" button of the winch. Too late! Now the winch just grinds and I can actually hold the cable by hand and stop it from retracting. The motor is good (I Hope), but the gears are stripped. Any thoughts on what the best fix would be? I am thinking of tearing it down and buying the parts or see what a new winch without all the mounting and electrical hardware would cost. It was an honest mistake, but unfortunately will make me go back to my old ways of not letting anyone use my stuff. I hate being like that, but they don't have the money to fix it and I am stuck with the repairs.

 

[1bush2hog]

Sorry to hear about your problem -

Maybe one of the following links will help you

www.warn.com/atv/winches/images/196/ATV66421A0.pdf

www.warn.com/atv/winches/25ci.shtml

 

[wally040]

The gears are probably ok. I would suspect the plastic housing with the plastic teeth is your culprit. Same thing happened to me & after tearing it down that was it. Just get a new end housing(new teeth) & follow the process from privious post & you'll be fine.

 

[cdover73]

Thanks guys. I will take the winch apart this evening to see what the damage is and then contact Warn to order the replacements.

 

[TOMMYHPX4X4]

this should help ya out a bit http://www.montanajacks.com/index.asp?PageAction=VIEWPRODGROUP&ID=6

 

[cdover73]

That was it. The plastic housing on the end with the freespool clutch. I called Warn and they actually sent me a new piece at no charge. The winch is over three years old so I thought it was nice of Warn to do that, even though the part was only $23. I now remember why I didn't want to work on the winch though. The mounting brackets are a pain! Too many bolts and too little room. I got it all back together yesterday and it works as good as new.
Thanks for the links and advice.

 

[SamIamfromNC]

Thanks guys. I will take the winch apart this evening to see what the damage is and then contact Warn to order the replacements.

Back in 2006 you posted about the same problem I'm having with my Warn 2.5ci winch. I was the one who pushed the "in" button too long and I'm certainly not a kid anymore. I was wondering what you did and what the outcome was. Mine reels the cable in and out but will no longer pull a load. I miss my winch...
Sammie