Ramsey Winch Company
OWNER’S MANUAL
ATV Electric Winch Model ATV 2500
BADGER 2500 WINCH
LAYER OF CABLE 1 2345
Rated line pull per layer (lbs) 2500 2090 1800 1580 1400
(kgs) 1133 947 815 716 634
CumulaƟve cable (Ō )* 7 15 25 37 50
capaci ty per layer ( m)* 2.12 4.56 7.6 11.3 15.2
(3/ 16" - 4.8mm - dia. cable)
*CABLE MUST BE UNIFORMLY WOUND ONTO DRUM.
Line pull ( lbs) NO 500 1000 1500 2000 2500
Įrst layer (kgs) LOAD 227 453 680 906 1133
Line speed (fpm) 18 17 15 12 11 7.5
Įrst layer (mpm) 5.5 5.1 4.6 3.7 3.4 2.3
Amp draw (12v) 36 60 90 116 140 160
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
Winch and safety procedures you need to
know before beginning use. When you follow
our guidelines for operation, your Ramsey
winch will give you many years of satisfying
service. Thank you for choosing Ramsey. You
will be glad you have one working for you.
Please Note: Ramsey ATV 2500 winches are
designed primarily for ATV use. This winch is
not designed to be used in industrial applications (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.
the most efficient operation from your Ramsey
CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND OPERATION OF WINCH. SEE SAFETY
PRECAUTIONS.
Contents
Performance Specifications…………. cover
Safety Precautions……………………. 2
Tips for Safe Operation……………….. 2
Techniques of Operation……………... 3
General Installation……………………. 3
Rocker Switch Installation……………. 4-5
Rocker Switch Operation……………… 5
Electrical Schematic (Rocker Switch)…6
Winch Operation………………………… 7
Maintenance ……………………………… 7
Cable Installation………………………… 7
Winch Parts List (Rocker Switch)…… 8-9
Trouble Shooting Guide…………………10
Warranty………………………………….. back cover
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 disen gaged. Always use hook strap to hold hook
when spooling.
M. Do not use the winch to hold a load while mov
ing. Secure the load with tie-downs. The winch
is not designed to be a load-holding device.
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.
F. Apply blocks to wheels when ATV is on an in cline.
G. Winch clutch should be disengaged when winch
is not in use and fully engaged when in use.
H. Modification, alteration, or deviation to the winch
should only be made by Ramsey Winch Com pany.
I. Keep the duration of your pulls as short as pos
sible. If the motor becomes uncomfortably hot
to the touch, stop and let it cool for a few min utes. Do not pull more than one minute at or
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.
Do not engage clutch with motor running.
Never connect the hook back to the cable. This
causes cable damage. Always use a sling or chain
of suitable strength.
2
Observe your winch while winching. If possible,
while standing at a safe distance.
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
If you use ATV
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.
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.
When pulling a heavy load, place a blanket, jacket or tarpaulin over the cable five or
six feet from the 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.
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 (21.6 Nm) 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.
CAUTION: SUPPLIED 7/8” LONG MOUNTING BOLTS WITH
LOCKWASHERS ARE FOR A RECOMMENDED WINCH MOUNT-
ING PLATE THICKNESS OF 3/16”. IF A DIFFERENT MOUNT-
ING PLATE THICKNESS IS USED, THE BOLT LENGTH MUST
BE ADJUSTED ACCORDINGLY OR DAMAGE TO WINCH MAY
OCCUR. REPLACEMENT BOLTS MUST BE SAE GRADE 5 OR
EQUIVALENT.
For basic self-recovery, anchor to a tree or heavy rock. When anchoring to a tree, always use a tree
trunk protector.
3. Do not attach motor and battery leads until
instructed to do so.
4. Refer to installation instructions for the Rocker
Switch on page 4 to install the Rocker Switch.
3
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.
2. Disconnect negative (-) battery cable from
battery. Turn off vehicle ignition.
3. Disengage winch clutch.
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.
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.
Installing the Rocker Switch
For clarification, see wiring schematic on page 6.
1. Position Tube Clamp (item #14-12) on handle
bars in convenient location.
AUTION: DO NOT CONNECT NEGATIVE BATTERY
C
CABLE OR ENGAGE CLUTCH UNTIL INSTALLATION IS
COMPLETE. WINCH 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.
2. Mount Rocker Switch housing to Tube Clamp
using #10 capscrew, locknut, flat washer, and
shake-proof washer (items #14-3, #14-5, #14-8,
and #14-9). Tighten securely.
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.
4
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
handles 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
AUTION: TIGHTEN NUTS ON TERMINAL STUDS TO 35-40
C
IN-LBS. (4-4.5 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 not connect.
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 6.
7. If winch spools cable IN instead of OUT, turn off
ignition and reverse yellow and green wires on
solenoid.
Rocker Switch
Operation
Press Rocker Switch toward
“IN” position to spool cable
“IN” and press Rocker Switch
toward “OUT” position to spool
cable “OUT”.
5
6
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.
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
ATV2500
1
10
Switch
Assy
2
6
3
11
5
7
8
5
11
10
7
4
3
4
9
6
2
12
8
9
1
BLACK
W/STRIPE
Solenoid
Wiring
Kit
13
1
2
RED
3
BLACK
14
4
BLACK
3
Hardware Kit
4
1
2
Switch
Wiring
Kit
12
8
Parts List
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 251214 MOTOR KIT
2 1 251247 MOTOR END GEAR SET
3 1 251191 CLUTCH KIT
4 1 251192 CABLE DRUM KIT
5 1 251213 CLUTCH END GEAR KIT
6 1 251236 ROLLER FAIRLEAD KIT
7 1 251195 BUSHING KIT
8 1 251196 TIE BAR KIT
9 1 251234 SOLENOID KIT
10 1 256116 BRAKE KIT
11 1 257536 ROCKER SWITCH KIT
12 1 299728 SWITCH WIRING KIT ¹
13 1 299724 SOLENOID WIRING KIT ²
14 1 257535 HARDWARE KIT ³
1
Switch Wiring Kit, as shown on facing page, consists of the following components:
ITEM NO. QTY. DESCRIPTION
12-1 1 123” RED WIRE
12-2 1 123” GREEN WIRE
12-3 1 123” YELLOW WIRE
12-4 1 24” LOOM
2
Solenoid Wiring Kit, as shown on facing page, consists of the following components:
ITEM NO. QTY. DESCRIPTION
13-1 1 37” MOTOR LEAD - BLACK W/YELLOW STRIPE
13-2 1 97” BATTERY LEAD - RED
13-3 1 97” BATTERY LEAD - BLACK
13-4 1 37” MOTOR LEAD - BLACK
3
Hardware Kit, as shown on the facing page, consists of the following components:
ITEM NO. QTY. DESCRIPTION
14-1 4 5/16-18UNC X 1” LG HX HD Z/P CAPSCREW
14-2 2 3/8-16UNC X 1” LG HX HD GR5 Z/P CAPSCREW
14-3 3 #10-24NC X 3/4 LG TRUSS CROSS RECESS F/B CAPSCREW
14-4 2 3/8-16UNC REG HX HD GR2 Z/P NUT
14-5 3 #10-24NC HEX LOCK NUT
14-6 4 5/16” MED Z/P LOCK WASHER
14-7 2 3/8” MED Z/P LOCK WASHER
14-8 3 #10 Z/P FLAT WASHER
14-9 1 #10 SHAKE-PROOF WASHER
14-10 1 WIRE SPLICE
14-11 1 PKG CABLE TIES (12 EA)
14-12 1 TUBE CLAMP
9
BADGER 2500 Trouble Shooting Guide
CONDITION
MOTOR RUNS IN ONLY ONE
DIRECTION
MOTOR RUNS EXTREMELY
HOT
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER OR
WITH LOW LINE SPEED
MOTOR RUNS, BUT DRUM
DOES NOT TURN
POSSIBLE CAUSE
Defective solenoid or stuck.
Defective Rocker Switch
Long period of operation.
Insufficient battery
Bad connection
Insufficient charging system.
Clutch not engaged.
CORRECTION
Jar solenoid assembly to free contacts.
Check each solenoid by applying
+12 volts to coil terminal (it should
make an audible click when energized).
Replace Rocker switch.
Cooling-off periods are essential to pre-
vent overheating.
Test for faulty battery.
Check battery cable for corrosion; clean
and grease
Replace with larger capacity charging
system.
If clutch engaged but symptoms still
exist, it will be necessary to disassemble
winch to determine cause and repair.
MOTOR WILL NOT OPERATE
MOTOR WATER DAMAGED
Defective solenoid or stuck
solenoid.
Defective Rocker Switch.
Defective motor.
Loose connections.
Submerged in water or water
from high pressure car wash.
Jar solenoid assembly to free contacts.
Check each solenoid by applying
+12 volts to coil terminal (it should
make an audible click when energized).
Replace Rocker switch.
If solenoids operate, check for voltage at
armature post; replace motor.
Check all electrical connections from the
battery to the motor.
Allow to drain and dry thoroughly, then
run motor without a load in short bursts
to dry windings.
10
NOTES
11
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 designated 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 dis-
claimer/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.
Quality Management System
RAMSEY WINCH COMPANY
P.O. BOX 581510 TULSA, OKLAHOMA 74158-1510 USA PHONE: (918) 438-2760
FAX: (918) 438-6888 http://www.ramsey.com
OM-914142-0813-B
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