Common Warn Winch problems??

[captain extreme]

Winch on my 2010 XT 800, has crapped out. Pretty much seems like the Lock and unlock is not engaging, Is this common, what should I look for once I start tearing it apart?

Thanks
Mike

 

[whoDEANie]

I've had three quads, three Warn 2500's, three freespools that stopped working after the first mud season. I'm kinda curious how to fix these myself, since the problem is likely to affect the winch operation eventually. ...but I will likely never use my freespool again since I just about got stranded once becuase I couln't re-engage the winch after freespooling it out.

 

[teeroy]

when you turn the freespool knob it pushes a shaft sideways disengaging the gears. sometimes enough material wears off the end of the plastic actuator that it won't push the shaft over far enough to disengage. I have taken mine apart, and used a welder to add a bit of material to the end of the shaft to make it work again with success.

 

[kbrunlees]

The newer ones with the red handle are supposed to be better, but as it was said they can wear out but you can get replacement parts. Just google warn winches and you can get the breakdown on them. The older model with the black star knob leak like a stuck pig and will chew the internals fairly quickly. They are pretty smple to take apart and clean just use a catch basin for the smaller parts. use a good waterproof grease to put them back together with.

 

[mudweiser]

Time to pull the winches and disassemble them for cleaning. Warn is not a fully sealed winch. While water will drain out, mud will not. everything is pretty simple in there. If you need some pics for assembly, check out warn's website and you'll find it. Don't forget to grease everything up upon re-assembly.

 

[250mark1]

the most common warn whinch problem is lack of maintenence they need to be cleaned and inspected at least once a year or more if you are into mudding a lot
clean them and fill them up completley with waterproof grease seems to help a lot imo

 

[doorfx]

Don't fill them with grease or they won't free spool worth a chit. Check this link
http://www.arcticchat.com/forum/att...ning-guide-winch_cleaning_instructions_v3.pdf

 

[doorfx]

I have a brand new 2500 with the red handle for sale if anyone needs one

 

[250mark1]

Don't fill them with grease or they won't free spool worth a chit. Check this link
http://www.arcticchat.com/forum/att...ning-guide-winch_cleaning_instructions_v3.pdf

the warn on the wifes quad free spools no problem and it is full of amsoil waterproof grease

 

[doorfx]

Must be the am soil synthetic. Regular grease makes it tough to pull out

 

[kbrunlees]

How much for the winch? Lahay99 his winch packed it in cuz it got bent, not sure how though.

 

[doorfx]

It's a kit it has everything switch , contactor ,wiring. $250 brand new