We should begin by sifting through the winch engine regulator from different winches. The winch motor is not turning. Truckbed? This may be due to a damaged motor, as described above, where you just get a clicking sound. My Warn winch won't spool cable in. Suggested Solution: Fully charge the battery. (Diagram 1) To test, connect a live cable to terminal F2. This may happen if you wire the winch incorrectly or if it’s been overheated. 16. Loud knocking noise from Gearbox. Clean it, and remove any corrosion using some fine sandpaper. Then repeat the test by switching the cables on the winch. Suggested Solution: Please refer to the procedure for re-greasing the gears when the winch won’t free spool. A winch out of control has the potential to inflict damage to your equipment or possibly cause severe injury to yourself or others. Yes, you need it to help protect the winch motor, especially when you consider it is cheaper to replace a solenoid than the motor. Winch runs in manual mode but not with wireless. Now that your winch is already disassembled, it may be a good idea to service the gears while you are at it. Not even making a click or a buzzing sound. A winch is a lifting device comprising a rope or chain around a rotating drum, which turns by crank or motor. If the winch starts working again, you have fixed the problem. You can compare the contactor to an ordinary relay. Also clean the housing for better results. The solutions are fairly easy and basic. Switching the wires on the motor terminals should reverse the running direction of the motor. If you have any doubts or lack the basic mechanical skills to perform the troubleshooting or repairs described in this post, you should rather take it to an authorized dealer and let them take care of it for you. Motor runs but with insufficient power or line speed. This site also participates in other affiliate programs and is compensated for referring traffic and business to these companies. The grease will create too much drag, making the gear hard to operate. Test first with the blue, then with the yellow. Dirt and other debris won’t help the situation either. (Or Slower?). If you put too much grease in the planetary gears, have used the wrong grease (too thick), or if the grease has gummed up due to water contamination and age, the gears will not turn as freely as they should. Connect the jumper cables to the battery. Winch jerks or makes grinding noises when pulling a load. If the winch works fine sometimes, but other times it just makes a clicking sound, the cause of the issue will likely be the same as when you always get clicking, and the winch never works. Another tip is to put the winch in a free spool position and use another winch to pull it out. Suggested Solution: In this case, the contactor needs replacing. A short happens when the positive (red) cable gets in contact with any metal part, like the bike’s frame, due to a damaged cable. One pad at a time. Suggested Solution: Remove the winch motor end cap. Use a short piece of wire to “jump” two of the opposing four (or three) pins. A faulty switch may also cause a short. Use some fine sandpaper or emery cloth and give both the motor end shaft and the inside of the bushing a light rub. Here are a few things you can do to find and repair the problems with your winch. Polarity does not really matter in this test. This leaves either the winch motor or the contactor. This is what determines which way the engine turns. The winch motor should operate as normal in one direction. The solenoids may be firing up, but they are not connecting. But they are not completely fail-proof. It may spool in but not out again, or it may spool out but without being able to spool it back in. Winches are designed to be used pulling a vehicle or to sit stationary as a part of a static pull. The basic principles on how to do the wiring should be the same on any winch. It turns out that I was right, the Warn Winch motor is made in China. If you have an air compressor available, use it to blow off any debris. Look for burnt spots or wear in the brushes. If you have any questions or suggestions regarding this article, please feel free to contact me. You can disassemble the knob to put everything back in place, but if your winch is affected by this issue, you will soon get it stuck again if you are not careful. Suggested Solution: If the fuse is blown, replace it with a new one with the correct amp rating. It may also be hard to get this ring gear to slide if someone mistakenly has applied grease on the outside of the gear or to the inside of the gear housing. Possible Solution: Clean the motor. The planetary gears themselves do not come apart. Motor will not operate or runs in one direction only. Why Aren’t All ATVs Four Wheel Drive? Some models have issues with the knob getting stuck due to bad design. Apply oil. ATV Mud Tire Weight Comparison (With Charts), Average ATV Trailer Weight (With 10 Examples), How Much Do ATV Tires Cost – Comparing Different Types, When the winch motor turns in only one direction, When the contactor is clicking, but the winch doesn’t work, When the winch works sometimes, but other times it doesn’t, When the winch turns very slow or lacks power when pulling, When the winch motor gets very hot very quickly, When the ATV winch won’t free spool or is tough to free spool, 10 Reasons Why Your ATV Battery Keeps Draining (Going Dead), How to Choose the Best ATV LED Light Bar – 10 Step Guide, How to Install ATV Tire Chains (Diamond and Ladder Style). Also, grease the bushings at each end of the spool. Unspooling the which line hooked to a vehicle, throwing the unstuck vehicle in reverse, and yanking it (kinetic pull) on the rig that is stuck is hard on the winches brake and the drivetrain. The next step should be the check of the ground contact. Finish cleaning odd old grease using a toothbrush or similar. The drum should move slightly. If the winch is old and just won’t turn on, there may be corrosion in the wiring. The cable itself may be damaged, or the connector at the contactor may have come loose. Inside the contactor, you’ll either find one two-sided or two single-sided solenoid magnetic coil switches. This works most of the time. I made this site to write about the things I have learned as an ATV owner. This one is widespread, and when it comes to troubleshooting, it has a positive side to it: When you hear an audible click sound, you know that the contactor is getting power when the switch is being pushed. (including Quick Connects) winch, and solenoid for loose or broken connections. 12. I cover the symptoms and how to fix three of the most common motor problems for DC and AC motors found in Power Tools and Appliances. Unmaintained or damaged motor Take off power bars Disconnect the battery from the bike, or use another battery so that you don’t damage the bike’s electronics. If the battery keeps draining, even after replacing it, the issue may be with the bike’s charging system. If you face issues with engaging or disengaging a winch that uses this type of knob, I suggest taking it to the dealer to get upgraded replacement pars if it’s still under warranty. (2) Defective remote control switch (2) Disengage winch clutch, remove remote control switch Add to Cart Fitments & Details. Step 1- Check The Clutch. Just follow the steps above, and you should find your problem. This may be due to corrosion or damage from overheating. And sometimes dirt may enter the motor housing, creating a dead short. Related: 10 Reasons Why Your ATV Battery Keeps Draining (Going Dead). Good, Reduced, or…, How to Replace the Valve Stem on a Tubeless Tire, How to Replace or Install an ATV Battery; Step-by-Step, How to Remove ATV or Motorcycle Grips Without Cutting. Suggested Solution: Try troubleshooting why it won’t engage as described earlier. Take breaks to allow the motor to cool down. Then try jumping the two other pins. Suggested Solution: Repair or replace any damaged cables or broken switches that are causing the short. If one works, but you get no reaction from the other, it has likely gone bad. (Power Distribution Module) See Component Troubleshooting, Reprogram PDM See Component Troubleshooting Replace (PDM) if necessary. See Component Troubleshooting, Check battery connections to (PDM) but not with wireless. Use some tape or alligator clips to connect the multimeter directly to the winch—one to the grounding and the other to the blue or yellow cable. If you can’t find any shorts in the wiring, a short may also be inside the winch itself or in the contactor—more on that further down. It will also point you in the right direction on how you should go about fixing them. I grew up on a farm where ATVs have been and still are an important part of “getting things done”. Also, make sure that the grounding cable on the winch motor housing is properly fitted. Disconnect all winch cables from the bike. Usually, there are 4, and you can see them at the base of the motor. Again, the cause of the issue maybe some sort of wiring issue. Most repairs are also simple, if it gets that far. winch motor repair - Minn Kota Minn Kota Deckhand 40 Electric Anchor Winch (40 Lbs. Pull the spool off. Gently tap the other terminal using the positive cable. Monday - Friday:8.30 - 5.00pmSaturday: 9.00 - 12:30 Sunday: CLOSED, Brookwell SuppliesPottery Road, Bovey TraceyDevon, UK, TQ13 9DSTel: +44(0)1626 833848, Brookwell Supplies3 Chantry Court, Marshall RoadCothill, Plympton, Devon, PL7 1YBTel: +44(0)1752 343443. A winch is, basically, a motorized spool and cable. A light coat of oil is all that should be used here. Remember to turn off the key and remove the battery terminals before you do any work on the winch. A completely dead winch often indicates that it’s not getting any power or that something is not grounded the way it should be. If the motor does not turn as normal when being fed power directly from the battery, you know it has some issue. Start with one pad, test continuity to every other pad. Set multimeter to VDC (volts, direct current). When your car gets stuck, you can use a winch attached to … Inside the winch, on many models, there is a ring gear that needs to slide freely sideways for you to be able to engage and disengage the winch. And as long as you steer clear of the cheapest models and you treat it well with some maintenance now and then, you should expect many years of hassle-free winching.
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