Required Tools and Supplies
- 10mm Socket
- 15mm Socket
- 4mm Allen Socket
- T25 TORX® Socket
- T27 TORX® Socket
- T30 TORX® Socket
- T40 TORX® Socket
- Ratchet
- Torque Wrench
- Flat-Head Screwdriver
- Pick
- Side Cutter
- Eye Protection
- Nitrile Gloves
- Shop Rags
To install the winch kit (part number 2890402 for the 4500-lb winch, part number 2890403 for the 6000-lb winch) on your RZR Pro R or Pro S, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key. Note: RZR Pro S 4 Ultimate Model with 6000-lb winch kit shown.
2. Begin by removing the driver’s seat by pulling up on the lever at the front of the seat.
3. Move the seat forward and move out of the slot to remove.
4. Disconnect the battery by removing the screw from the negative battery connections and disconnect the negative cables with a 10mm socket.
5. Turn the two knobs counterclockwise to remove the grill from the vehicle.
6. Remove and keep the two screws from the side of the bumper using a T40 TORX® socket. Repeat on the other side. Then remove the bumper from the vehicle.
7. Remove four screws from the factory bumper using a T40 TORX® socket and remove the front plate of the bumper.
8. Remove two push-pins from top of the bull bumper using a flat-head screwdriver.
9. Remove four screws from the bull bumper with a 15mm socket and remove the bull bumper from the vehicle.
10. Remove two screws from the center hood with a T40 TORX® socket to remove the center hood panel from the vehicle.
11. Continue by opening the center dash storage lid to remove and retain the two screws using a 4mm Allen socket.
12. Disconnect the USB port wiring and lift the center storage out of the dash.
13. If equipped, remove the front tweeter speakers by removing the two screws from the A-pillar cover with a T27 TORX® socket.
14. Remove the tweeter hooks from the A-pillar cover and disconnect the tweeter from the vehicle.
15. Set the tweeter speaker aside.
16. Move the A-pillar cover up to the ROPS tube.
17. Remove the dash by removing and keeping two screws from the dash panel using a T40 TORX® socket.
18. Remove and keep the screw from the dash side panel using a T40 TORX® socket. Repeat on the other side.
19. Open the glove compartment by lifting it upward, and remove and keep four screws from the interior of the glove compartment using a T30 TORX® socket.
20. Remove the center control panel. Pull on the top and bottom edges to disengage the four mounting tabs.
21. Pull the dash panel out and up to remove from the vehicle.
22. To install the winch, begin by finding the two hooks on the rear of the winch assembly.
23. Find the slots in the front frame piece.
24. Continue by putting the winch assembly onto the vehicle by fitting the hooks into the slots.
25. Attach the winch assembly with a 15mm socket using the two provided screws in the upper mounting locations and two screws in the lower mounting locations. Torque to 37 ft-lbs (50 Nm).
26. Install the harness by removing and keeping one fastener from the front fascia bracket using a 10mm socket. Remove and keep the bracket.
27. Route the harness along the radiator shroud. Attach the shroud using edge clips. Note: Reference written instructions for routing guidance.
28. Route the harness above the shock absorber and attach it to the suspension bracket using edge clips.
29. Use cable ties to attach slack areas of the harness to the chassis.
30. Locate four mounting holes for the contactor box at the front right side of the body tub.
31. Install the contactor box using four screws and a T25 TORX® socket and torque until fully seated.
32. Continue by routing the harness through the grommet at the front of the vehicle. Tip: It may help routing to remove the grommet and slide forward on the harness, then re-install the grommet.
33. Locate the Pulse bar at the front of the dash area.
34. Connect the harness to the Pulse bar.
35. Attach the positive and negative harness connections to the Pulse bar using two nuts and a 10mm socket. Torque until fully seated.
36. Attach the harness to the vehicle frame using an edge clip.
37. Install the front fascia bracket and torque to 88 in-lbs (10 Nm).
38. To install the winch switch, begin by removing the switch hole cover from the chosen switch location with a flat-head screwdriver.
39. Continue by routing the winch control harness through the switch opening.
40. Install the winch switch into the switch opening. Make sure the wires do not become pinched and the switch clicks into place.
41. Connect the winch switch harness to the main winch harness.
42. To install the winch cover, begin by putting the bumper on the front of the vehicle.
43. Attach the bumper using four screws and torque to 88 in-lbs (10 Nm).
44. Install the winch cover on the bumper using four screws and torque until fully seated.
45. Continue by installing the grill by turning the two knobs to lock the grill.
46. To reinstall the dash, place the dash to the vehicle frame by pushing forward and down to engage tabs on the underside of the panel.
47. Align the mounting tabs at the top and bottom of the center audio panel and push the panel into place.
48. To install the wireless remote holder, use two screws and tighten with a T25 TORX® socket until fully seated. Note: Polaris recommends installing wireless remote in the location shown. Wireless remote can be installed in any desired location.
49. Place the wireless remote into the holder.
50. Loosely install the four kept screws to the inside of the glove compartment. Torque to 31 in-lbs (3.5 Nm).
51. Close the glove compartment.
52. Loosely install the kept screw to the inner dash panel. Repeat on the other side.
53. Loosely install the two kept screws in the top of the dash panel. Torque all screws to 31 in-lbs (3.5 Nm).
54. Place the dash storage in the dash opening and connect the USB port wiring.
55. Attach the storage bin using the two kept screws and tighten until fully seated. Close the storage bin.
56. If equipped with tweeter speakers, connect the tweeter to the vehicle audio harness through the dash hole.
57. Continue by moving the A-pillar cover down the ROPS tube.
58. Install the tweeter hooks into the A-pillar cover holes.
59. Install the A-pillar cover to the vehicle with two screws.
60. Install two screws to the center hood panel and torque to 31 in-lbs (3.5 Nm).
61. Continue by connecting the negative cables to the negative battery terminals and torque to 44 in-lbs (5 Nm).
62. Test the winch to ensure proper operation.
63. Install the driver seat by placing the front seat pivot into the mounting slot. Tip the seat back to lock into place.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
More maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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Unless noted, trademarks are the property of Polaris Industries Inc.
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