Thanks, got it figured out, the drive coupler off the motor was broke. Go out to Warn’s site and download the parts manual for your winch. That will show the parts in the correct orientation. The drawings aren’t super-detailed, though. If you find the manual doesn’t give you the answer, post some pics and we’ll try to figure it out for you.
If the winch starts working again, you have fixed the problem. After you have determined what’s causing your problem, you’ll find a suggested solution to the issue. This will lead you to the root of the problem much faster than by just randomly testing all the different things that can go wrong. A winch out of control has the potential to inflict damage to your equipment or possibly cause severe injury to yourself or others. Luckily, there is a lot you can do yourself to troubleshoot and repair an ATV winch that doesn’t work as it’s supposed to.
Table of Contents
Motor runs only in one direction
Simply remove the bolt holding the lever in place, and wiggle the lever out. Also, note that operating the winch over a long period may also overheat it, with the risk of permanently damaging the motor. Take breaks to allow the motor to cool down. Other times it just makes the situation a lot worse. Also, grease the bushings at each end of the spool. Wear a rubber glove and use your finger to apply a nice even but not too thick coating on every gear except the sliding ring gear.
It died sometime after extracting a forklift from the sand out back at the farm supply store I worked at. Warn asked me to send it in so I did, then a couple weeks later I received a BRAND NEW winch in the mail. They said that it failed internally in the motor and replaced the entire thing. That winch is still in use on the 53 Willys CJ today.
What Is the Biggest ATV? (By Size, Hp, Torque, Weight)
Lifetime warrenty exept for electric motor. I sent ine in last year and it works great. Disassemble the winch to inspect the gears, and replace them if needed. Whether it is due to using the winch, the clutch not being completely engaged, or from incorrect use like towing or yanking, the gears may be stripped. The grease will create too much drag, making the gear hard to operate.
Under it there is a snap ring that holds cap on. Pins move in and out by rotating metal clip. And then last weekend I was pullin a bunch of guys out and mine started freespooling on it’s own.
Cause 1: Burr on the sliding ring gear, creating drag against the inside diameter of the gear housing
Just to sum up this thread that was the problem Icon. That little metal disc was getting caught on the plastic when I would try and lock it back. I just filed the edges off and now it works perfectly. Surprisingly wasn’t too much mud in there and I could see exactly what the problem was as soon as I took the clip off and go that plastic piece off. I went through some stuff but it was mostly deep water riding down the creek plus I pressure washed it out once I got home to no avail.
A light coat of oil is all that should be used here. Now that your winch is already disassembled, it may be a good idea to service the gears while you are at it. The lever needs to come out to be cleaned, and any rust must be removed.
Motor running but either slowly or without enough power
It’s also possible that there’s a problem with the motor’s installation or that it’s overheating. The remedy to all of the difficulties listed above is to thoroughly clean the batteries as well as the wire connections. You’ll also need to replenish the battery and replace the brush set as well as the motor. You could also check where your wires from the switch lead. Mine were wrapped around the steering column pretty tight and everytime i had the wheels turned to the right it would pull them out and not winch in. The provantage or front mount plows pose a problem if the whinch cable isn’t vertical.
This did not serve them well as they had to call several of their winches because of these faulty contractors as they could have started a fire even. In this article, we are going to talk about the Common Warn Winch Problems we will likely face with our warn winch and find suitable solutions to them. Actually my plow IS a belly mount plow underneath. My winch never lets the plow fall slowly. It’s located on the inside of the frame on passenger side near front shock. Cool thanks, my 2013 just got stuck disengaged after I winched myself out of a huge hole…
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Looks like a pulley would have to be mounted 6+ inches out from the winch. Now imagine that same cable being at 45 deg. 1/2 of the winches lifting force is being used to lift the plow – and the other 1/2 is being used to TRY and pull the plow backwards towards the quad.
The solenoid bump these contacts together in order to deliver the correct current to the motor. These contacts bumping into each other are what causes the clicking sound you hear. There are a few possibilities when your Warn winch solenoids just click but the motor doesn’t work.
Cause 4: Too much or old grease in the gears
I’m not the one who actually turned it to freespool so it wouldn’t surprise me if he overturned it or something. It will turn a little towards freespool but won’t turn any towards the lock. It was charitable of Warn to use a solonoid that is not common with any that are stocked at Napa for automotive use…bastards. The rest of the winch is decent, the cheap solenoids are probably just to reach the price point.
Use some fine sandpaper or emery cloth and give both the motor end shaft and the inside of the bushing a light rub. Just follow the steps above, and you should find your problem. If the winch works as normal when you power it with jumper cables, the issue will very likely be in the contactor. Because of the wet and muddy conditions that lead you to get a winch in the first place, the solenoids may rust over time. Rusted plungers will not move freely, so that you don’t get proper contact. If the winch motor starts and runs in both directions when performing the test, the switch itself is likely faulty.
Warn winch failures
I used to work in construction and landscaping, so I’ve seen my fair share of ratchet straps, winches, and similar rigging gear. I started Winch Central because I’ve seen some nasty accidents due to crappy rigging or poor practice. I wanted to be able to recommend good equipment that’s SAFE and also provide resources for how its used. I handle the research side of things here as well as product selection for gear analysis. If your Warn winch has “died” it may be just a faulty remote control and not the winch itself. According to many winch users, the remote control stops working properly quiet often.
Learn to Diagnose Your Winch Problems
To avoid these types of issues, you should always let your winch drain out completely after the operation is done. Once that is done, run the engine in short bursts without any load for further drying. Your issue could also be related to the whole charging system of the motor. Meaning that the motor is not getting the right amount of energy. To fix this, you will be required to change the whole chagrin system. The primary reason for insufficient power is probably that the battery does not have enough charge.
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