Ramsey Winch Install on Suzuki King Quad ATV, for Off-Road.com

Aug. 01, 2005 By Heath Williamson
Who really needs a 3000# winch on their ATV? Most winch manufacturers recommend a pulling capacity at least 1.5 times gross vehicle weight so using the 5 to 1 factor this winch provides I would need a 40,000# winch on my crew cab pickup, that's cool. Seriously to fully use the winch you need to anchor your ATV to something solid, but this abundance of power should make even the most difficult extractions a piece of cake. I choose the Ramsey winch because of my good experiences using their full size winches on a couple of outings with friends who needed that 40,000# winch I mentioned earlier. The remote control is a handy feature in that in extremely awkward or off camber winching activities you only need to be within range of the transmitter, about 25 feet when I was testing after the install. This will put you safely out of the way when the unexpected happens. So follow along as I begin the installation. Believe it or not it really does help to read the instructions before you start. I did, but, the most helpful part was the wiring diagram which picked up where the instructions left off. Here we go…..
I started the installation by laying out all of the pieces. This allows you to ensure you've got everything and get a feel for how it all goes together. You will need a selection of hand tools and drill bits to complete the installation. The only item I used that isn't shown here is automotive Goop. I'll explain that later.
 
Suzuki thought ahead and provided winch mount points for the base plate. My only complaint is that they are of light guage material and welded to thin wall frame tubes. I don't believe these attachment points would hold up to heavy pulls over time. The winch mount itself is of sturdier stuff. Formed of 3/16” plate and powder coated black, it should hold up to years of use/abuse. The winch itself comes with a roller fairlead, which is a nice touch when most only come with a hawse type. Ramsey also makes available an aluminum hawse fairlead for use with synthetic line, which has the advantage of not recoiling and separating you from your appendages if it should happen to break.
 
As you can see I've got the winch mount and fairlead installed in the frame using the supplied hardware. We purchased an aftermarket mount from eWinch.com intended for use with this model winch and it is a precise fit. I tried to limit the number of body panels removed, but I ended up removing everything that wasn't yellow by the time I got done, so I would recommend starting out by doing just that. The best place I could find to install the solenoid was right here behind the front bumper fascia. It's in the airflow but not exposed and with the tightly packed drive train, was the only place I could find to make it fit and still have the leads all reach where they need to go.
 
Suzuki provides this handy piece of flexible conduit to run the power leads for the solenoid through. At least that's what I used it for. It worked great and keeps them out of harms way. The plastic conduit terminates where the red and black leads run up in front of the battery tray. Quick, Simple and Easy.
 
In addition to the remote control for your key ring, Ramsey included a 2-position toggle switch for those times when your remotes batteries go dead. Usually when needed most! The toggle switch is installed on the left side of the headlight pod, between it and the gear selector lever. This location was the best combination of accessibility and protection from branches and front rack loads. Shown here is the receiver. With the tightly packed drive train under the left side engine cover provided the best access and protection. I formed up the grey mount out of some 14 gage steel and sandwiched it between the frame and a torque mount that limits the engines twist. It's a tight fit the side cover just clears the receiver by a quarter inch of so.
 
The antenna is mounted up under the front plastic just behind a black plastic grill. This was very difficult for me to get my fat fingers into and I thought very well protected. The antenna mounts using double backed sticky tape. The antenna mount is the only part of the kit I found to be cheap. The directions tell you to wipe the proposed area for antenna installation down with rubbing alcohol then stick the three part antenna into place. I did just as instructed. The antenna stayed in place for about 5 miles then fell off. I reattached it with Automotive Goop and a zip tie through the small grill and we had no more problems. Notice the minimal winch-to-radiator clearance. This picture was taken with the winch and the mount pulled firmly forward before they were tightened down. It's only about a 1/16 ” To me that's too tight but the winch never contacted the radiator so its no real problem so far.
 
Here you see the front fascia reinstalled and the final routing of the wiring. (“Fascia” - never thought I'd use that term while talking about a rough and tough ATV.) My only shot of the winch in action while spooling the line tightly on the winch drum to complete the installation. I really did try to get stuck, but the Suzuki was doing its best to churn its way through the stickiest mud and steepest climbs I could find.

One final thought - pick up a few of Suzuki's plastic rivets before you even start. I managed to ruin two while removing the plastic. Good luck with your own winch installation, and better luck with getting stuck enough to test it! We have since used this winch to pull large trees out of the trail, though it was nearly dark and the camera wasn't easily at hand, so you'll have to take our word for it.  


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