Created: April 21, 2020
Hey everybody, today I’m going to be showing you how super easy it is to install SuperATV’s winch and winch mount on the Polaris RZR PRO XP. So let’s jump right in.
First, remove the upper portion of the dash. Remove the two T40s holding the hood on, then remove the hood and set it aside. Remove these T40s as well and these two push pins so we can move the plastic around.
Grab this latch and flip it up so you can open up this center storage compartment. These can get stuck on the clips sometimes so I just like to take a push pin removal to and just pry straight up on it. Pull it out and pull out the little rubber boot to remove the USB port.
[1:23]Come over hear and open up this compartment where we’ll remove all four of the T20 screws. Then use a pushpin removal tool or something that can pry up on this plastic with and start right here. Just pry up and this piece will come off.
Now remove these 3 T40 screws. Then do the same thing with the panel on the driver’s side. Remove these T40 screws. Then pry off this panel. Then remove these T40 screws. this one’s tough to get to but if you pull the steering wheel all the way up you can reach it. Put the steering wheel back down and lock it to keep it out of the way.
[3:50] Now the dash is loose and you should be able to rock it around and pull it towards the steering wheel. It will be tight, but it will come out. Once you get it up and over the top slide it like this. Then go to the passenger side and grab the upper dash. I’m just going to throw it up on the roof to keep it out of the way.
Now we’ve gained access to the pulse bar. We already have our pulse plug installed right here, which can be purchased from SuperATV.com. We have our ground and our hot wire and we’re going to use the pulse plug to get our keyed on power source.
[4:36] At the front bumper of the machine, remove these four T40s to remove the center section of the fascia. Then remove these T40s to remove the front portion of the fascia and the grille. Then remove the hardware for the front bumper. There will be two bolts back here through this hole, and two up front. Then remove the two pushpins down through this hole and remove the front bumper. Remove all four of these bolts and remove the mount.
Now get the winch and winch mount out of the boxes. Right now you need the winch hardware and the fairlead hardware. The winch mount will install to the machine just like this, so we’ll need to make sure that our wiring connections are on the passenger side.
To do that, we’re going to take the winch and lay it onto the mount. Grab the rope and slide it up through the hole where the fairlead is going to be. Take the hardware that comes with the winch—a bolt a flat washer and a lock washer—slide the mount to the edge of the table, line up the holes, and slide the bolt through. Do this for both sides. Once all the hardware is started, tighten all four bolts in an X pattern.
[8:06] Rotate the winch up like this and grab the fairlead. Feed the rope through it and slide the fairlead all the way up to the winch mount. Grab the grab the fairlead hardware and mount the fairlead to the plate. After both screws are started, make sure the fairlead is centered and straight and tighten them up. They don’t have to be super tight.
Now grab the clevis hook and pull the pin out of it and attach it to the winch rope. Make sure you add the cotter pin. Now grab the stop block and screws. You’ll use two washers per screw and they’ll go in the block just like this. The cut out goes towards the clevis hook. Once all the hardware is started, fully tighten all four.
Now grab four M10 x 30 mm bolts out of the hardware kit and two M10 nylock nuts. For these two holes down here, we’re going to use two of our M10 x 30s with no nuts. They’ll thread right in. For these two holes, we’ll use our M10 x 20s with the nylock nut.
[10:59] These bolts will go through these holes in the winch mount. here on the top right and the top left. Grab the winch mount and lay it into place and get the bolt started. If you reach around on the backside, you can hold it in place a little bit with your knee or if you have somebody to help you that makes it a lot easier.
Get the hardware started on both sides and pick up on the winch mount to get the lower holes lined up. Thread the bolts right in. Once everything’s started, go through and start tightening up the hardware.
Since we haven’t run the winch wires or anything yet, there’s two ways you can do this. You could have run the wires with the winch loose or not installed at all, but we’re just going to remove this one 10 mm bolt and bracket to run our wires. It’s super easy.
No reinstall the front bumper and fully tighten the hardware. We’ll wait until we get everything wired up before we reinstall the fascia and grille.
[13:08] Next, grab the solenoid for the winch out of the kit, and one of the screws needed to attach the solenoid to the machine. Slide the screw through the bottom hole here, then come to this section under the dash. There are three holes right here. Slide the screw through the bottom hole and line it up to tighten it. Then mark a spot in the plastic for the top hole, then drill it out. Next we’ll mount up the solenoid.
Take the phillips head screw and start with the top hole. Then do the lower. Once you have the hardware started, fully tighten it.
Next grab the red and black wire. We’re going to attach the black wire to the ground on the solenoid here at the black post. And then we’ll attach the ground wire over here on the busbar. Go ahead and remove the nut that’s holding the ground cable onto the busbar.
[15:35] We’ve already pre-cut our wires to length. Run the ground wire down then back up then attach it right here to the ground post and thread the nut back on. Fully tighten it once it’s lined up. Then attach the ground to the solenoid too. Run the hot wire down here. Attach it to the busbar and the solenoid.
Next grab the yellow and blue wires. We’re going to run these wires down the same route as the hot and ground and run them all the way to the floorboard. Take these wires and run them under the hot wire then attache it to the post.
Find this grommet in the firewall on the passenger side, and cut a slot in it big enough to feed your wires through. Feed the wires through as far as you can. Then we’ll go to the front to route them.
[19:57] We took our pulse busbar plug out to show you which wire we’re going to connect to get our keyed on source. The orange wire here is the keyed on power source. This is going to connect to the red wire on our SuperATV rocker switch which can be purchased with the kit. I highly recommend you do. It makes it a lot nicer and easier. However, you can complete the install without this switch, and connecting the keyed on power source is going to be the same on the harness that comes with the winch. You’ll still have a red wire. This is still going to be your keyed-on source wire and you’ll need to connect it to the orange wire.
We already stripped these wires. Go to the rocker switch panel and feed the wire down into the dash right about where we fed the winch wires through. Feed all the slack through and pop the rocker switch right into place in the dash. You can shorten this harness, but there’s going to be quite a few wires in there and you’d have to make all your connections so I usually just roll it up and zip tie it.
Tuck the wires in and connect it to the plug coming off the side of the solenoid. Now we’re ready to make the connection with the keyed on power source. Make sure you connect the red wire from your rocker switch to the orange wire on your pulse plug. Now take the pulse plug and plug it right back in to the busbar. Take the excess wire, loop it up, and zip tie it.
[23:25] Now lift the machine so you can make the connections in the front of the machine. I like to run my blue and yellow wires through the heat shrink. It’s not necessary but it looks a little bit nicer and adds a little bit more protection.
Now feed them down toward the winch. Run them alongside the radiator hoses and through this hole right below the radiator hose. Rune the yellow one through the hole first and it goes back in behind the winch. Then feed the blue one through. Then you’ll be ready to make your connections.
Loosen this bracket, put the cover on the yellow wire, and connect it to the terminal. Then do the same for the blue wire.
Next, tighten all the connections on the top of the solenoid. After that, put the covers on each of the posts. Then reinstall the grille and fascia. Then reinstall all the hardware. Slide the winch rope through this piece and then attach it using the factory hardware. We’ll go through and make sure all the hardware is tightened and double check all our wiring. Make sure the winch is working then reinstall the dash.
And that’s how super quick and easy it is to install SuperATV’s winch and winch mount on the Polaris RZR PRO XP.