How to Troubleshoot an ATV Winch

ATV winches can enhance an outdoor experience when riding. The cable can be attached to fallen tree limbs for clearing a trail. A winch can also mean the difference from being stuck in a mud hole and pulling the vehicle free to continue on your way. Checking the winch for proper operation before your trip can save a lot of headaches. If a problem arises you can troubleshoot the winch at home using the following basic process.

Things You'll Need

• Pliers Screwdriver Toothbrush Vinegar Voltmeter Battery charger Small wooden stick

Instructions

1. Check all wire connections with the pliers and screwdriver. Tighten any loose connections. Inspect the wires for any signs of corrosion. Corrosion on wire can come in the form of a white or green powder-like substance.

2. Clean the corrosion with a toothbrush and vinegar. Dip the bristles into the vinegar and rub the corroded area.

3. Use the voltmeter and confirm that the voltage is correct from the battery. Plug the red lead into the "volt" connector and the black lead into the "common". Touch the black lead probe end to a bare place on the ATV frame. Place the red lead to the positive (+) side of the battery. Turn the voltmeter to the "DC Volts" position on the switch. Read the meter. It should read at least 12.5 volts. Charge the battery if the reading is below 12 volts.

4. Confirm the operation of the remote switch using the voltmeter. Keep the black lead on a bare part of the frame. Touch the red lead to one side of the solenoid coil wire that comes from the switch. Depress the switch in both directions for 2 seconds. The meter should read at least 12 volts. Perform the same test for the other wire that comes from the remote switch. If one side of the switch fails to register, the switch is bad. Replace the switch.

5. Tap the solenoid with a small wooden stick to engage the solenoid contacts. If all the above steps have checked out, the contacts in the solenoid may not be touching. Can you hear an audible click when the switch is depressed? Depress the switch and tap the outer plastic case gently. If the solenoid fails to engage the solenoid is bad. Replace it.

6. Engage and disengage the mechanical free wheel clutch. Pull on the cable when the clutch is disengaged. Engage the clutch while pulling on the cable. This can clear a stuck gear lever.

7. Check the motor for "hot" operation. The motor will generate a lot of heat when being used. Allow the motor to cool. Constant heat emitting from the motor under light loads can be a sign of excessive use. The motor may have to be replaced in a short period of time.

Tips & Warnings

• Always keep an eye on the cable for any signs of fraying and loose wires. Cables in this state should be replaced. Apply a small dab of grease on the electrical connections if they form excessive corrosion. The grease will aid in sealing out moisture. Keep the battery charged when the ATV is not in use. A winch can consume more power than some ATV alternators can recover.

References

• Off Road Winches
• ATV Winch Manual