2004 500 with warn winch issue

[germanshorthairs]

I just tried to use my winch and all it does is click when I push IN or OUT. It makes the clicking by the solenoid. Checked the fuses and they are fine. Any ideas on what is wrong. The snow with fly soon and I need to fix this. Thanks in advance.

[gunmunky]

Check to make sure you have at least 12 volts going to the winch. I had a winch on my Jeep and it did the same thing. When I checked the voltage it read 11.8. I found out that I had to have a minimum of exactly 12 volts (or more) for it to work. Hope this helps.

[Surface Tension]

Check the voltage as said. If that checks out I'd bet your brushes are warn and because of that, stuck too from brush dust.

You can get the a brush kit, install isn't too bad.

[Bjjams]

What model is it? I have a 2.5ci I got around 2004 that had the same issue. It was the contactor. I called warn about it I found out it was on recall so they sent me the part free.

[Dave S]

I was going to throw the contactor out as an option too. Heard of many cases involving the contactor.

[Surface Tension]

He is hearing the contactor(a type of relay)click.

Check the voltage coming off that and to the the winch.

[Surface Tension]

I'll add that even if the contactor tests good, check to see if it has a recall. If my memory is right, your right around that year.

[Bjjams]

Mine clicked like germanshorthairs described as well. Here is the recall notice.

http://www.warn.com/atv/recall_notice.shtml

[Surface Tension]

Check to make sure you have at least 12 volts going to the winch. I had a winch on my Jeep and it did the same thing. When I checked the voltage it read 11.8. I found out that I had to have a minimum of exactly 12 volts (or more) for it to work. Hope this helps.

I didn't see your post.

Good call.

[S.D. Ice Angular]

Sounds like a corrosion problem with the wiring.

[germanshorthairs]

Thanks for all the replies, I will do the voltage check as suggested and then I will get back to you all. I am also going to see if it is a recall model. If it is I will get a new contactor coming.

[germanshorthairs]

Update, I have 12 volts to the contactor and 0 volts to the winch?? So I think it is the contactor. I checked the warn HSOforum and this one was built by warn for arctic cat and is NOT included in the recall. Not a big deal. My problem now is finding the part. It is not on the warn HSOforum, that I could find and I could not find it on any oem arctic cat websites so I am at a lose. Also, it was starting to squeal(the motor)prior to stopping and I would like to replace brushes, but once again don't know how to get parts other than replacing the whole thing. I will keep u updated. Thanks again!

[Bjjams]

It might be worth it to call warn directly and see what they can do. They have real good customer service.

[germanshorthairs]

Well, I got some answers. I have to buy the contactor from arctic cat at ($80). They cannot sell you a brush replacement kit. You have to buy a new motor at ($190). A new 2.5ci winch is only 300 so I may just buy the whole thing.

Surface Tension-where do you buy just the brush kit?? If it is like any other electric motor I am assuming it is a lot less than $190 for a whole motor??? Thanks

[Dave]

Call Warn anyhow.....they (and Superwinch) are "usually" VERY good at just taking your name and address and sending a contactor out.

[Surface Tension]

It might have been Northern Kawasaki but they recently closed shop. Or NAPA? Let me check with my buddy, it was his winch I was working on and I had him pick it up. He is in Saskatchewan till next week. Arctic Cat btw.

So when you tested for voltage you went to one of the + coming off the conductor that goes to one of terminals on the winch. Other lead you went straight to ground and then tried both in and out, right?

The squeal you mentioned I don't think is a brush issue.

You know you can disconnect the power cables going to the winch and direct connect with a jumper cable to test the motor.

[germanshorthairs]

Have been busy with other things so I put this project on a little hold. I have not tried jumping it yet. Let me know when you find out where to get the brushes. I will call warn again, but they insisted I had to go to a cat dealer???

[Surface Tension]

Sorry about not getting back to you sooner.

The brush kit was from Northern Kawasaki, as I said they are out of business. BUT the kit brand was from Kimpex.

The squealing isn't caused by the brushes though.