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Mounting a Winch on a 99 Kawasaki Prairie 400 4x4 http://pilotodyssey.com/PO/viewtopic.php?f=5&t=5018	Page 1 of 1

Author:

MassOdy [ Fri Jan 02, 2009 9:06 pm ]

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Mounting a Winch on a 99 Kawasaki Prairie 400 4x4

I got a new 2000 Lbs Winch for christmas.

I wanted to put it inside the front bumper.
The kits I could find made it look like they all mount it outside the bumper.

So I started to craft up a bracket.

more to come.

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Author:

MassOdy [ Fri Jan 02, 2009 9:07 pm ]

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couple more

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Author:	Ody_Stable [ Sat Jan 03, 2009 12:09 am ]
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Dude...... That foil tape and cardboard just aint gonna do it!!!! Only good for about 10lbs of pull....... Ya need some 3M strapping tape and some good 1/8" melamine to do it right.......

Author:

MassOdy [ Sat Jan 03, 2009 5:01 pm ]

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I had a awesome time at the shop today.
Amazing how fast we were able to build the mount from spare stock.

Just need to finalize the mounting hardware and make a new front grill to fit.

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Author:

MassOdy [ Sat Jan 03, 2009 5:04 pm ]

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Author:	hoser [ Sat Jan 03, 2009 5:40 pm ]
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Nice almost ready to winch something ?

Author:	MassOdy [ Sat Jan 03, 2009 5:58 pm ]
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Final touches on the tab hardware to squeeze. and drill two more mounting bolts inside further. I'm not going to do the electrical until the mechanical is all set. Then route wires accordingly. As a secondary task: I'm also going to add a front spot/search light and the backup camera for plowing. Also considering a second battery as a reserve.

Author:	Sunblock [ Sat Jan 03, 2009 7:10 pm ]
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looks good, is that one of those gorilla's? Let us know how it works out, I have been thinking of getting one also.

Author:	MassOdy [ Sat Jan 03, 2009 7:59 pm ]
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My Wife went to the tractor supply. They sold her a winch for the Kabota UTV. The guys were cool and all when I went back to get a mount kit. But, nothing was for certain. I always wanted to install one inside the protected areas. I tore down the Kawi to look and decided we can do this. I'll be sure to post back results. I also now need to upgrade my rope bag to include winching hardware. But, mostly its for plowing my driveway and dragging dead trees. And this mount is my real first metal project since Jr High School. LOL

Author:	MassOdy [ Sat Jan 03, 2009 8:06 pm ]
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Also meant to say: It is a SuperWinch TV2000 from what I can tell.

Author:	adnoh [ Sun Jan 04, 2009 1:49 pm ]
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Be sure to post up some in use pics like hanging upside down from tree. Nothing like cool christmas presnts. I used to get items like that untill She ( wife) fiqured out I would run out to garage and play. Konw I get socks and set on couch and watch T.V. with her. Nice job, Enjoy.

Author:	bubba66 [ Sun Jan 04, 2009 2:25 pm ]
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You ever look at the synthetic winch cable. I got one a couple of years ago and it works great for me. I got tired of trying to pick a bunch of tiny pieces of metal out of my hand everytime I used the steel cable. Just my $.02.

Author:	hoser [ Sun Jan 04, 2009 2:38 pm ]
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bubba66 wrote: You ever look at the synthetic winch cable. I got one a couple of years ago and it works great for me. I got tired of trying to pick a bunch of tiny pieces of metal out of my hand everytime I used the steel cable. Just my $.02. Fray cables are caused by misuse or abuse.

Author:

MassOdy [ Sun Jan 04, 2009 6:11 pm ]

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I'll abuse this one first then look into it on the replacement cable. ;)

Couple things I did to improve the installation.
I wrapped the split loom and wires with an extra coat of electrical tape. Shrink tubing would have been an other option.
I find this help keeps the wires inside out of the mud and wetness.

The switch I used SS Cushion clamps to mount to handle bars. And SS hardware.
The screws to hold the cover will get a dab of silicon on them and later replaced with SS when I fins tiny ones.
I put a bead of silicon around the seam of the electrical box and tightened it down. Once dry I'll wrap the last wires in tape.

No breaks in the wiring from battery (Circuit breaker) to switch to Winch and the switch is water tight.

Fun little project. Little more to do still ran out of weekend.

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Author:

MassOdy [ Sun Jan 04, 2009 6:13 pm ]

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Oh and added an old spot light I had from an old project too.

The winch mount squeezes the ATV tubing well. I can still had a couple more bolts if need be.

I get a ton of plow clearance now. And much easier on the arm.

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Author:

Nuke Em [ Sun Jan 04, 2009 10:07 pm ]

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Very Nice! I did the same thing a couple of days back to my Suzuki Eiger 400 4X4(adding a snow plow, Warn winch was already there). I already had a dump bucket on it but that thing just sucked for snow plowing. I am having lighting issues with the plow on, guess I need to add some fog lights! Nice write-up with pics.

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Author:	MassOdy [ Mon Jan 05, 2009 10:20 am ]
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Thanks! Nice machine BTW. I wondered about those buckets. I have troubles with deep snow here and could use to chop the banks off. But, a tractor is really needed instead. How does your winch do being low and in the mud at times. For a plow lifter I think mine is in a good spot. But, as a drag me out I think lower and closer to the front axles would have been better. I was looking at the manual plow lifter assembly last night. At least 60% of the parts fo rhe plow can be removed now the winch will do the work of lifting.

Author:

Nuke Em [ Tue Jan 06, 2009 12:23 am ]

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MassOdy wrote:

Thanks! Nice machine BTW.

I wondered about those buckets. I have troubles with deep snow here and could use to chop the banks off.
But, a tractor is really needed instead.

How does your winch do being low and in the mud at times. For a plow lifter I think mine is in a good spot.
But, as a drag me out I think lower and closer to the front axles would have been better.

I was looking at the manual plow lifter assembly last night. At least 60% of the parts fo rhe plow can be removed now the winch will do the work of lifting.

The main trouble I had with the bucket in snow was that it filled up then you had to dump it and most of the time the packed snow didn't want to come out. Also, when it was full of heavy snow the winch would not hold it up very long while driving along. Maybe I need a heavier duty winch? Its a 2000 lb Warn.

I do not do much "mudding" in wyoming so I have not had any problems so far. I got the whole thing for $1000 from a neighbor. It wasn't running right and he was moving and didn't want to mess with it. The main jet had a dead bug stuck in it, damned-est thing I ever seen, no clue how it got past the filter. I love easy fixes!

Kids use the bucket to haul split firewood to the house, probably more fun than the truck. lol I may use it for moving dirt around on my atv track this summer. I put the scrapper bar on the bucket that has points to help break up stuff when digging.

Gary

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