Note: Fairlead does not attach directly to winch. Winch
shown with mounting plate (P/N 251073), sold separately.
Model ATV2500
Congratulations
You have purchased the finest winch available in its service class. It features a highly efficient 3 stage
planetary gear set which transmits torque from a permanent magnet motor. A safe positive clutch allows
free spooling for quick cable deployment. Your Ramsey winch was designed and manufactured to provide
you with the utmost in utility. As with any device that combines power and movement in its use, there are
dangers if improperly used.
At the same time, there are easier and faster ways for getting the job done if certain precautions are taken
first. Please read this manual carefully. It contains useful ideas in obtaining the most efficient operation
from your Ramsey Winch and safety procedures you need to know before beginning use. When you follow our guidelines for operation, your R
you for choosing Ramsey. You will be glad you have one working for you.
Please Note: R
cations (car haulers /carriers, wreckers, hoisting, etc.), and Ramsey does not warrant it to be suitable for such use. Ramsey makes a
separate, complete line of winches for industrial/commercial use. Please contact the factory for further information.
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE SAFETY PRECAUTIONS.
TV 2500 winches are designed primarily for A
amsey A
amsey winch will give you many years of satisfying service. Thank
TV use. This winch is not designed to be used in industrial appli
winch should only be made by Ramsey Winch
Company.
I. Keep the duration of your pulls as short as
possible. If the motor becomes uncomfortably
hot to the touch, stop and let it cool for a few
minutes. Do not pull more than one minute at
or near the rated load. Do not maintain power
to the winch if the motor stalls. Electric
winches are for intermittent usage and should
not be used in constant duty applications.
J. Do not use winch in hoisting applications due
to required hoist safety factors and features.
K. Do not exceed maximum line pull ratings
shown in tables. Shock loads must not
exceed these ratings.
L. To respool correctly, it is necessary to keep a
slight load on the cable. Do not allow the
cable to slip through your hand and do not
approach the winch too closely. When all the
cable except a few feet is in, stop and finish
spooling in cable by rotating the drum by hand
with clutch disengaged. Always use hook
strap to hold hook when spooling.
Safety Precautions To Guard
Against Possible Injury.....
A. Keep yourself and others a safe distance to
the side of the cable when pulling under load.
B. Do not step over a cable, or near a cable
under load.
C. Use supplied hook strap when handling hook
for spooling wire rope.
D. Do not use ATV to pull a load on the winch
cable. This could result in cable breakage
and/or winch damage
E. Use a heavy rag or gloves to protect hands
from burrs when handling winch cable.
. Apply blocks to wheels when A
F
incline.
G. Winch clutch should be disengaged when
winch is not in use and fully engaged when in
use.
TV is on an
Tips for Safe Operation
Don't underestimate the potential danger in winching operations. Neither should you fear them. Do
learn the basic dangers and avoid them.
Observe spooling of cable onto drum. Side pulls
can cause cable to pileup at one end of the drum.
To correct uneven stacking, spool out that section
of the cable and move it to the other end of the
drum and continue winching. Uneven spooling
which causes cable pileup can interfere with the
winch tie rods causing damage to the winch.
Store the wireless remote control transmitter in a
safe place where it will not become damaged.
Inspect it before you use it.
When ready to begin winching, push and hold the
On/Off button on the transmitter until it flashes.
Do not engage clutch with motor running.
2
Page 3
Never connect the hook back to the cable. This
causes cable damage. Always use a sling or
chain of suitable strength.
Observe your winch while winching. If possible,
while standing at a safe distance. If you use ATV
drive to assist, stop and get off every few feet to
assure the cable is not piling up in one corner.
Jamming cable can break your winch.
Do not attach tow hooks to winch mounting apparatus. They must attach to ATV frame.
When double lining during stationary winching,
the winch hook should be attached to the chassis
of the ATV. Since the greatest pulling power is
achieved on the innermost layer of your winch, it
is desirable to pull off as much line as you can for
heavy pulls. If this is not practical, use a snatch
block and double line arrangement.
Neat, tight spooling avoids cable binding which is
caused when a load is applied and the cable is
pinched between two other wraps of cable. If this
happens, alternately power the winch in and out a
few inches. Do not attempt to work a bound
cable under load, free by hand.
Techniques of Operation
The best way to get acquainted with how your
winch operates is to make a few test runs before
you actually need to use it. Plan your test in
advance. Remember you hear your winch as well
as see it operate. Get to recognize the sound of a
light steady pull, a heavy pull, and sounds caused
by load jerking or shifting. Soon you will gain
confidence in operating your winch and its use
will become second nature with you.
Your winch will not only pull your ATV up or ease
your ATV down a steep grade, it will also pull
another ATV or a load while your ATV is anchored
in a stationary position.
When pulling a heavy load, place a blanket, jacket
or tarpaulin over the cable five or six feet from the
, anchor to a tree or heavy rock.
y
or basic self
F
When anchoring to a tree, always use a tree trunk protector.
-recover
hook. It will slow the snap back in the event of a
broken cable.
Use the ATV wheel power to help the winch, but
don't overtake the winch line. Plan your pull.
You can't always hook up and pull out in one step.
Examine all the areas for anchoring possibilities
as well as leverage situations, direction, and goal.
Winches equipped with cable guide fairleads can pull
from several directions. Pull from an angle only to
straighten up the ATV--otherwise you can damage structural members or other parts of your ATV and cause
excess cable buildup on one end of the winch drum.
General Installation
The winch shown in this owners manual is solely
and exclusively designed for ATV mounted, nonindustrial applications. All other applications will
void warranty.
1. Install Winch and Mounting Kit according to
instructions supplied with Mounting Kit.
Tighten mounting bolts to 16 ft-lbs torque.
2. It is very important that the winch be
mounted on a flat surface, with the cable
feeding from the bottom of the drum.
AUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS WITH
C
LOCKWASHERS ARE FOR A RECOMMENDED WINCH MOUNT
ING PLATE THICKNESS OF
PLATE THICKNESS IS USED, THE BOLT LENGTH MUST BE
ADJUSTED ACCORDINGLY OR DAMAGE TO WINCH MAY
. REPLACEMENT BOLTS MUST BE SAE GRADE 5 OR
OCCUR
EQUIVALENT
.
3. Do not attach motor and battery leads until
instructed to do so.
4. Refer to installation instructions for the
Wireless Remote Switch (in the ATV WirelessInstallation and Operation Manual), the
Remote Mounted Manual Switch (on page 13
of this manual), or the Rocker Switch (page
19) for installation of the appropriate switch
and electrical assemblies for the winch.
3
3/16”. IF A DIFFERENT MOUNTING
-
Page 4
Rotating the Motor on your ATV
Winch
The ATV winch has the motor studs and leads
positioned on the end of the motor aligned vertically. If you need to rotate the motor on your ATV
winch to gain clearance, you can rotate the motor
90°. The motor studs will then be aligned horizontally.
Before you begin:
Note: If you have installed the optional Brake kit
(P/N 256116) for the ATV winch, make sure you
have the Brake kit installation instructions before
proceeding. You will need to re-install the Brake
kit after you rotate the motor (step 6 on the following pages). Contact Ramsey if you do not
have your installation instructions.
1. Remove the cable from the drum. Turn the
clutch handle to Freespool and pull cable. Slide
the end of the cable out of the pocket again the
drum flange until the cable anchor can be
removed. Be sure to keep the cable anchor for
re-installing the cable. Leave the clutch set to
Freespool.
2. Disconnect the motor leads.
3. Remove the winch from its mounting channel.
Place it on a sturdy, level workbench.
Set the winch down on the clutch end.
1. Remove the tie bar bolts and nuts. Pull tie bars
from between end bearings.
2. Lift the motor end off the drum and set down
with the motor end down. Make sure the shaft,
drum bushing and spring stay with the drum.
4
Page 5
3. Remove the bolts that hold the end plate to the
motor end housing. Lift off the end plate and
take the nuts and washers out of the mounting
feet. Set aside the gear assemblies and bushing. The input sun and planetary gear carrier
may come out together.
4. Lean the motor end and loosen the motor tie
bolts off the tie bolt nuts. Lean the motor end
back up so that it is sitting upright. Do not let
the motor end cap come apart from the
rest of the motor. Lift the motor end housing
and rotate 90°. Put the tie bolt nuts in the other
set of pockets and carefully lean the motor end
back. Tighten the tie bolts to 45-50 in-lbs.
torque. Do not overtighten.
5. After rotating the motor, the motor end will
appear as shown at right. The motor studs will
be aligned horizontally, and the motor tie bolt
nuts will be in the other set of pockets.
5
Page 6
6. Replace the gears into the motor end housing,
fitting the input sun gear over the motor shaft.
The planetary gear carrier should be seated so
that the bushing, as shown at lower right, is
flush with the ring gear.
7. Re-install the end plate on the housing with
the bolts you removed earlier. Tighten these
bolts to 45-50 in-lbs. torque. Do not overtighten.
8. Lift the motor end assembly onto the drum.
Turn the drum and motor end assembly so
that the shaft fits into the input sun gear.
Lean the motor end assembly slightly to one
side to insert the tie bars into their holes.
9. Slide the tie bar bolts through the tie bars and
into their nuts. Tighten the tie bar bolts to 4550 in-lbs. torque. Do not over tighten. The finished winch should look as shown below,
with the motor studs aligned horizontally.
Confirm that the drum freespools properly without
binding.
Refer to the winch mounting kit installation
instructions for re-installing the winch. Re-install
the winch cable according to the instructions in
this manual.
Insert the mounting nuts and washers into the
pockets of the housing as shown. Make sure they
do not fall out while re-installing the end plate.
6
Page 7
Winch Operation
The winch clutch allows rapid unspooling of the
wire rope for hooking onto the load or anchor
point. The clutch is operated by the shifter located
on the end of the winch as follows:
1. To disengage the clutch, turn the clutch
shifter to the "FREESPOOL" position. Wire
rope may now be freespooled off the drum.
2. To engage the clutch, turn the clutch shifter to
the "ENGAGED" position. The winch is now
ready for pulling.
All moving parts in the winch are permanently
lubricated with broad temperature range lithium
based grease. Under normal conditions factory
lubrication will suffice.
Lubricate cable periodically using light penetrating
oil. Inspect for broken strands and replace if necessary. If the cable becomes worn or damaged, it
must be replaced.
Cable Installation
Note: Cable should be installed so that it
feeds from the bottom of the drum.
Unwind the new cable by rolling it out along the
ground to prevent kinking. Remove old cable and
observe the manner in which it is attached to the
cable drum flange, watching carefully for the
cable anchor puck.
Before installing the new cable assembly, securely
wrap the end of the cable with tape to prevent
fraying.
Your battery must be kept in good condition. A
fully charged battery and proper connections are
essential. Run the vehicle engine during winching
operations to keep battery charged.
Maintenance
Corrosion on electrical connections will reduce
performance or may cause a short. Clean all connections. In salty environments use a silicone
sealer to protect from corrosion.
To minimize corrosion of the internal motor components that may occur due to condensation,
power the winch in or out periodically. Energizing
the motor will generate heat, which will help dissipate any moisture buildup in the motor. This
should be performed at periodic intervals (such
as with each oil change to your vehicle). Note:
Refer to Troubleshooting Guide if the motor has
been submerged.
See supplied instr
replacement transmitter.
uctions for programming a
The short end of the cable should
extend approximately 1/8” beyond
the top edge of pocket.
Slide the cable through narrow end of the pocket
against drum flange and wrap the cable around
the anchor puck. Pull the cable and anchor back
into the wide end of the pocket leaving approximately 1/8” beyond edge of pocket as shown.
Use a hammer and drift punch to drive the back
side of the wire rope, firmly seating the wire rope
and anchor into the pocket.
Wind on the cable by pulling in a light load to
keep the tension constant. Allow the cable to
swivel by using a length of chain or a swivel
block between the cable hook and the load.
7
Page 8
ATV2500 Trouble Shooting Guide
CONDITIONSPOSSIBLE CAUSECORRECTION
MOTOR RUNS IN ONLY ONEDefective solenoid or stuck solenoid. Jar solenoid assembly to free contacts.
DIRECTION (Wireless remote only)Check each solenoid by applying
Defective remote controlCheck winch operation with auxilliary
or low battery in transmitter.toggle switch.
(Wireless remote only)
Defective Manual or R
(Manual or Rocker switch only)
MOTOR RUNS, BUT WITH Insufficient battery Test for faulty vehicle battery.
INSUFFICIENT POWER
OR WITH LOW LINE SPEEDBad connectionCheck battery cable for corrosion;
Insufficient charging systemReplace with larger capacity charging
MOTOR WILL NOT OPERATE Defective solenoid or stuck solenoid. Jar solenoid assembly to free contacts.
Defective remote control Check winch operation with auxilliary
or low battery in transmitter.toggle switch.
(Wireless remote only)Check transmitter battery.
Defective Manual or Rocker switch. Replace Manual or Rocker switch.
(Manual or Rocker switch only)
ocker Switch Replace Manual or Rocker switch.
+12 volts to coil terminal (it should
make an audible click when energized).
Check battery in transmitter.
clean and grease
system.
ble winch to determine cause and
repair.
Check solenoid by applying 12 volts to
coil terminal (it should make an audible
click when energized).
Defective motorIf solenoids operate, check for voltage
Loose connections.Check all electrical connections from
MOTOR KIT
MOTOR END GEAR SET KIT
CLUTCH KIT
CABLE DRUM KIT
CABLE & HOOK KIT
CLUTCH END GEAR KIT
ROLLER FAIRLEAD KIT
BUSHING KIT
TIE BAR KIT
ELECTRICAL WIRING KIT
WIRELESS RECEIVER & TRANSMITTER KIT
WIRELESS TRANSMITTER KIT
SOLENOID KIT
TOGGLE SWITCH KIT
ANTENNA KIT
HARDWARE KIT*
Wireless Remote Control
Operation
Refer to page 6 of Wireless Remote Control
Installation Instructions for remote operation
notes. Refer to pages 2-4 of Installation
Instructions for instructions for installing the solenoid, receiver, antenna, and toggle switch.
AUTION:WHEN THE TRANSMITTER REACHES A
C
TEMPERATURE BELOW
OPERATE
. IN EXTREMELY COLD TEMPERATURES, KEEP
TRANSMITTER IN A POCKET OF INNERMOST LAYER OF
CLOTHING WHEN NOT IN USE
The transmitter has push buttons labeled according to their function. Make sure the motor has
stopped fully before reversing to prevent premature solenoid failure. To operate the winch hold
“ON/OFF” button for 2 seconds to activate the
“IN” and “OUT” functions. Run winch forward and
reverse to check connection and to verify winch
operating directions. The transmitter is clearly
labeled and a red LED flashes when the winch is
in operation. Pushing both buttons at the same
time will not damage your winch in any way.
ress and hold the “ON/OFF
P
mitter to disable the transmitter when winch is not
in use. This will prolong the battery life of the
transmitter. The transmitter automatically turns off
after 20 minutes.
RED W/WHITE
STRIPE SOLENOID/
IGNITION WIRE
(Item #12-6)
SOLENOID ASS’Y.
TTERY
BA
BLACK SOLENOID
GROUND LEAD
(Item #12-7)
RED
BATTERY LEAD
(Item #12-1)
12
Page 13
Manual Switch Operation
Rotation of the switch clockwise spools cable
“IN” and counterclockwise spools cable “OUT”.
Manual Switch Installation
The Remote Mounted Manual Switch can be
mounted at any convenient location on the ATV
that is close enough to the winch so that connections can be made without altering wire lengths.
Before Beginning Installation
1. Install mounting kit and winch according to
the mounting kit instructions.
4. Remove hood or cowling as necessary for
easier access to installation area.
5. Locate and mark mounting locations for
Manual Switch and Solenoid Assembly.
6. Locate accessory wire from vehicle ignition
switch that is powered only when ignition is
ON. Use this wire when splicing to solenoid.
7. Make sure locations are close enough for
wiring connections to be made without making alterations to wire lengths.
Solenoid Mounting: Choose a mounting location
that will remain protected and dry. Solenoid must
be mounted within 24” of vehicle battery.
Solenoid should be mounted on a flat surface. A
good location where possible is under the seat
.
next to the batter
y
Connect Wiring to the Remote Mounted
Manual Switch
For clarification, see wiring schematic on page
12.
Note: The four terminals on the switch are
labeled (-, +, 1, and 2).
CAUTION: TIGHTEN TERMINAL NUTS ON MANUAL SWITCH TO
30 IN-LBS. (3 NM) TORQUE. DO NOT OVER-TIGHTEN.
1. Connect Black Battery Lead (Item #12-2) to
(-) terminal on switch and route to negative
(-) vehicle battery terminal but do not connect.
2. Connect Red Switch Lead (Item 12-3)
between (+) terminal on switch and
Solenoid.
3. Connect Black w/Yellow Stripe Motor Lead
(Item #12-5) between #1 terminal on the
switch and #1 terminal on motor.
4. Connect Black Motor Lead (Item #12-4)
between #2 terminal on the switch and #2
terminal on motor.
Install Splice
1. Push Accessory wire from ignition and Red
w/White Stripe Solenoid wire into plastic
Splice (Item #13-1).
2. Fold splice clip over itself and snap closed.
Connect Wiring to Solenoid
CAUTION: TIGHTEN NUTS ON LARGE STUDS TO 50-60 IN-
. (5-7 NM) TORQUE. TIGHTEN NUTS ON SMALL STUDS
LBS
15-20 IN-LBS. (1-2 NM) TORQUE. DO NOT OVER-
TO
.
TIGHTEN
1. Connect Red Battery Lead (Item #12-1)
between Solenoid and positive (+) vehicle
battery terminal.
2. Connect Red w/White Stripe Solenoid wire
between Ignition Switch Splice (Item #13-1)
and Solenoid.
3. Connect Black Solenoid Ground wire to
Solenoid and route to negative (-) vehicle bat
tery terminal but do not connect.
-
13
Page 14
Installing the Manual Switch
CAUTION: BE SURE THAT NO WIRE CONNECTIONS ARE IN
CONTACT WITH EITHER THE
OTHER AS A DIRECT SHORT WILL OCCUR
ATV FRAME OR WITH EACH
.
The Manual Switch can be mounted to either a
tube or a flat surface such as a fender.
Attach Mounting Plate and Insulator Plate to
Manual Switch (with wires attached) using (4)
1/2” long Phillips head screws included with the
Switch Assembly. The Insulator Plate goes
between the Mounting Plate and the Manual
Switch, centered with the switch base.
Hint: If you are mounting switch to flat surface,
mark mounting holes before assembling switch.
Tube Mount
Use (2) 1/4” u-bolts and (4) Nylok nuts to install
to a tube up to 1” diameter. Tighten to 30 in-lbs.
(3 Nm) torque. Do not overtighten. If over-
torqued, the mounting plate may warp and
affect switch operation.
Installing the Solenoid
1. Use Solenoid Assembly as a guide to mark
and drill (2) 5/16” holes in location determined for solenoid.
2. Use (2) 1” long 1/4” capscrews, (2) 1/4” flat
washers (as needed), and (2) 1/4” Nylok nuts
to mount solenoid. Tighten to 60 in-lbs (7
Nm) torque.
Finish Installation
1. Confirm that winch clutch is disengaged.
2. Connect negative battery cable to battery.
Connect Black Battery Lead (Item #12-2)
and Black Solenoid Ground wire (Item #12-
7) to negative (-) vehicle battery terminal.
3. With ignition switch OFF, turn Manual Switch
to “OUT” position—winch should not operate.
If the winch does operate with the ignition off,
confirm that proper accessory wire from ignition was spliced.
4. Turn ignition switch ON and Manual Switch to
“OUT” position—winch should operate. If
winch does not operate with ignition and
Manual Switch ON, check wiring to the
schematic on page 12.
5. Spool a few feet of cable out by hand.
Engage clutch. Turn Manual Switch to “OUT”
position and confirm that cable spools out. If
cable spools in wrong direction, check wiring
against the schematic on page 12.
Flat Surface Mount
Use switch mounting plate as a guide to mark and drill (4) 5/16” holes in flat surface.
Use (4) 1” long 1/4” capscrews, (4) 1/4” flat washers (as needed for fender mount),
and (4) 1/4” Nylok nuts to mount manual switch. Tighten to 30 in-lbs. (3 Nm) torque.
Bottom View
op View
T
14
Page 15
NOTES
15
Page 16
ATV2500 (Manual Switch)
10
Switch
Assy
1
11
2
3
6
11
13
Hardware Kit
6
7
5
9
9
5
4
3
4
8
7
8
10
2
1
12
12
Wiring
Kit
1
RED
RED
ACK
5
BL
W/STRIPE
2
BLACK
6
3
BLACK
4
ACK
BL
RED
7
16
Page 17
ATV2500 (Manual Switch) Parts List
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
* Wiring Kit, as shown on facing page, consists of the following components:
ITEM NO.QTY.DESCRIPTION
12-11BATTERY LEAD - RED (24” LONG)
12-21BATTERY LEAD - BLACK (96” LONG)
12-31SWITCH LEAD - RED (96” LONG)
12-41MOTOR LEAD - BLACK (48” LONG)
12-51MOTOR LEAD - BLACK W/YELLOW STRIPE (48” LONG)
12-61SOLENOID/IGNITION - RED W/WHITE STRIPE (72” LONG)
12-71SOLENOID GROUND - BLACK (30” LONG)
MOTOR KIT
MOTOR END GEAR SET KIT
CLUTCH KIT
CABLE DRUM KIT
CABLE & HOOK KIT
CLUTCH END GEAR KIT
HAWSE FAIRLEAD KIT
BUSHING KIT
TIE BAR KIT
SOLENOID KIT
REMOTE MOUNTED MANUAL SWITCH ASSY
WIRING KIT*
HARDWARE KIT**
**Hardware Kit, as shown on the facing page, consists of the following components:
ITEM NO.QTY.DESCRIPTION
13-145/16-18UNC X 1” LG HX HD Z/P CAPSCREW
13-223/8-16UNC X 1” LG HX HD GR5 Z/P CAPSCREW
13-361/4-20NC X 1” LG HX HD Z/P CAPSCREW
13-421/4-20NC X 1 X 1 3/4” Z/P U-BOLT
13-523/8-16UNC REG HX HD GR2 Z/P NUT
13-661/4-20NC NYLOK Z/P NUT
13-745/16” MED Z/P LOCK WASHER
13-823/8” MED Z/P LOCK WASHER
13-961/4” FLAT Z/P WASHER
13-1041/4” THREAD PROTECTOR - BLACK VINYL
13-111WIRE SPLICE
13-121 PKG CABLE TIES (12 EA)
17
Page 18
Electrical Schematic (Rocker Switch)
ROCKER SWITCH
IN
YELLOW WIRE
OUT
BLACK MOTOR
LEAD
MOTOR
#2
RED WIRE
#1
GREEN WIRE
SOLENOID ASS’Y.
BLACK W/ YELLOW
STRIPE MOTOR
LEAD
BLACK
BATTERY LEAD
For certain mounting applications, where the solenoid
needs to be mounted at the rear of the vehicle, switch
the battery and motor leads. In this case, connect the
black w/yellow stripe lead to the positive (+) terminal
of the battery, and the longer black lead to the negative (-) terminal. Connect the red lead and the shorter
black lead to the motor terminals.
E
C
A
B
RED
BATTERY LEAD
SPLICE
TO ATV IGNITION
NOTE:
TORQUE SOLENOID
TERMINAL NUTS TO
35-40 IN-LBS.
BATTERY
18
Page 19
Rocker Switch
Operation
Press Rocker Switch
toward “IN” position to
spool cable “IN” and
press Rocker Switch
toward “OUT” position
to spool cable “OUT”.
Installing the Solenoid
1. Use Solenoid Assembly as a guide to mark
and drill (2) 7/32” holes in location determined for solenoid.
2. Use (2) 3/4” long #10 capscrews (item
#14-3), (2) #10 flat washers (item #14-8),
and (2) #10 locknuts (item #14-5) to mount
solenoid. Tighten to 60 in-lbs (7 Nm) torque.
Rocker Switch Installation
The Rocker Switch will mount to the handle bars
of the ATV.
Before Beginning Installation
1. Install mounting kit and winch according to
the mounting kit instructions.
4. Remove hood or cowling as necessary for
easier access to installation area.
5. Locate and mark mounting location for
Solenoid Assembly.
6. Locate accessory wire from vehicle ignition
switch that is powered only when ignition is
ON. Use this wire when splicing to Red wire
on Rocker switch.
7. Make sure locations are close enough for
wiring connections to be made without making alterations to wire lengths.
CAUTION: DO NOT CONNECT NEGATIVE BATTERY CABLE OR
ENGAGE CLUTCH UNTIL INSTALLATION IS COMPLETE
COULD BEGIN SPOOLING CABLE UNEXPECTEDLY CAUSING
INJURY OR DAMAGE TO WINCH
.
Solenoid Mounting: Choose a mounting location
that will remain protected and dry. Solenoid
should be mounted on a flat surface.
. WINCH
Installing the Rocker Switch
For clarification, see wiring schematic on page
18.
1. Position Tube Clamp (item #14-12) on handle
bars in convenient location.
2. Mount Rocker Switch housing to Tube Clamp
using #10 capscrew, locknut, flat washer,
and shake-proof washer (items #14-3, #145, #14-8, and #14-9). Tighten securely.
19
Page 20
3. Push the Green, Red, and Yellow wires
through the back of the switch housing.
4. Install the Gasket onto the Rocker Switch.
5. Connect Yellow wire (item #12-3) to top terminal on Rocker Switch (terminal behind “IN”
position). Connect Red wire (item #12-1) to
middle terminal on Rocker switch. Connect
Green wire (item #12-2) into bottom terminal
of Rocker switch.
6. Slide Green, Yellow, and Red wires into loom
(item #12-4). Slide loom up to back of the
switch housing.
7. Snap switch and switch housing together.
8. Push Accessory wire from ignition and other
end of Red wire into plastic Splice (item #14-
10).
9. Fold splice clip over itself and snap closed.
10. Route wires from Rocker Switch down the
handle bars. Turn the handle bars fully right
and left to ensure plenty of clearance.
11. Make sure wires are not drawn taut across
any surfaces that could damage them. Use
cable ties to anchor wires. Tie off excess.
Connect Wiring to Solenoid (unless motor and
battery leads are switched)
CAUTION: TIGHTEN NUTS ON TERMINAL STUDS TO 35-40
IN-LBS. (3-4 NM) TORQUE. DO NOT OVER-TIGHTEN.
1. Connect Red Battery Lead (Item #13-2)
between “A” terminal on Solenoid and positive
(+) vehicle battery terminal.
2. Connect Black Motor Lead (item #13-4)
between #2 terminal on motor and C terminal on solenoid. Connect Black w/Yellow
Stripe Motor Lead (item #13-1) between #1
terminal on motor and B terminal on solenoid.
3. Connect Black Battery Lead (item #13-3) to
“E” terminal on Solenoid and route to negative (-) vehicle battery terminal but do notconnect.
4. Plug Yellow wire from switch into right terminal (terminal above black with yellow stripe
motor lead). Plug Green wire from switch into
left terminal (terminal above black motor
lead).
Finish Installation
1. Confirm that winch clutch is disengaged.
2. Connect negative (-) battery cable to vehicle
battery. Connect Black Battery Lead from
winch to negative (-) vehicle battery terminal.
3. With ignition switch OFF, press Rocker switch
to “OUT”—winch should not operate. If the
winch does operate with the ignition off, confirm that proper accessory wire from ignition
was spliced.
4. Spool a few feet of cable out by hand. Engage
winch clutch.
5. Turn ignition switch ON and press Rocker
switch to “OUT”—winch should spool cable
out.
6. If winch does not operate with ignition on,
check wiring to the schematic on page 18.
7. If winch spools cable IN instead of OUT, turn
off ignition and reverse yellow and green
wires on solenoid.
20
Page 21
NOTES
21
Page 22
ATV2500 (Rocker Switch)
ACK
BL
W/STRIPE
1
10
Switch
Assy
1
11
2
3
5
12
14
Hardware Kit
4
BLACK
6
7
5
9
7
4
3
10
4
8
8
6
2
1
11
9
Switch
Wiring
Kit
4
12
13
Solenoid
Wiring
Kit
2
RED
3
BLACK
3
1
2
22
Page 23
ATV2500 (Rocker Switch) Parts List
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1. Switch Wiring Kit, as shown on facing page, consists of the following components:
ITEM NO.QTY.DESCRIPTION
12-11123” RED WIRE
12-21123” GREEN WIRE
12-31123” YELLOW WIRE
12-4124” LOOM
2. Solenoid Wiring Kit, as shown on facing page, consists of the following components:
ITEM NO.QTY.DESCRIPTION
13-1137” MOTOR LEAD - BLACK W/YELLOW STRIPE
13-2197” BATTERY LEAD - RED
13-3197” BATTERY LEAD - BLACK
13-4137” MOTOR LEAD - BLACK
3. Hardware Kit, as shown on the facing page, consists of the following components:
ITEM NO.QTY.DESCRIPTION
14-145/16-18UNC X 1” LG HX HD Z/P CAPSCREW
14-223/8-16UNC X 1” LG HX HD GR5 Z/P CAPSCREW
14-33#10-24NC X 3/4 LG TRUSS CROSS RECESS F/B CAPSCREW
14-423/8-16UNC REG HX HD GR2 Z/P NUT
14-53#10-24NC HEX LOCK NUT
14-645/16” MED Z/P LOCK WASHER
14-723/8” MED Z/P LOCK WASHER
14-83#10 Z/P FLAT WASHER
MOTOR KIT
MOTOR END GEAR SET KIT
CLUTCH KIT
CABLE DRUM KIT
CABLE & HOOK KIT
CLUTCH END GEAR KIT
ROLLER FAIRLEAD KIT
BUSHING KIT
TIE BAR KIT
SOLENOID KIT
ROCKER SWITCH KIT
SWITCH WIRING KIT
SOLENOID WIRING KIT
HARDWARE KIT
1
2
3
23
Page 24
Warranty Information
Ramsey Winches are designed and built to exacting specifications. Care and skill go into every winch we make. If
the need should arise, warranty procedure is outlined on the back of your self-addressed, postage paid warranty
card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have any
problems with your winch, please follow instructions for prompt service on all warranty claims.
Limited Lifetime Warranty
Ramsey Winch offers a limited lifetime warranty for each new Ramsey ATV winch against manufacturing defects in workmanship and materials on all
manufactured components.
Warranty registration cards for each winch must be submitted at the time of purchase, or within 90 days. Online registration of your winch is available at www.ramsey.com.
New cable assemblies are warranted against defects in workmanship and materials. No warranty applies after initial use.
All Ramsey mounting kits and other accessories carry a 1- year limited warranty against defects in materials and workmanship.
This warranty is void if winch is used in commercial/industrial applications other than front mount self recovery.
Electrical components consisting of motors, solenoids, wiring, wire connectors, and associated parts carry a limited 1-year warranty.
The obligation under this warranty, statutory or otherwise, is limited to the replacement or repair at the manufacturers factory, or at a point designat-
ed by the manufacturer, of such part as shall appear to the manufacturer, upon inspection of such part, to have been defective in material or workmanship. This Warranty does not obligate Ramsey Winch Company to bear the cost of transportation charges in connection with the replacement or
repair of defective parts, nor shall it apply to a product upon which repairs or alterations have been made, unless authorized by the manufacturer, or
for equipment misused, neglected, or improperly installed.
Important notice: To the fullest extent permitted by applicable law, the following are hereby excluded and disclaimed:
1. All warranties of fitness for a particular purpose;
2. All warranties of merchantability;
3. All claims for consequential or incidental damages.
There are no warranties that extend beyond the description that appears on the face hereof.
Some states do not allow the above exclusions or disclaimers in consumer transactions and as such this disclaimer/exclusion may not
apply to your particular case.
To the extent such warranties of fitness for a particular purpose or merchantability are deemed to apply to this product, they exist only
for so long as the express limited warranty elsewhere set forth is in existence.
Ramsey Winch Company makes no warranty in respect to accessories, same being subject to the warranties of their respective manufacturers.
Ramsey Winch Company, whose policy is one of continuous product improvement, reserves the right to improve any product through changes in
design or materials as it may deem desirablewithout being obligated to incorporate such changes in products of previous manufacture.
If field service at the request of the buyer is rendered and the fault is found not to be with Ramsey Winch Company’s product, the buyer shall pay the
time and expense of the field representative. Bills for service, labor or other expenses which have been incurred by the buyer without express approval
or authorization by Ramsey Winch Company will not be accepted.
This Warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.