Leaderboard

I still have my original warn winch on my 2007 machine. I have replaced the cable twice already, but I also plow with it. I have taken it apart and cleaned it according to this guide probably 3 or 4 times. One time after cleaning it would not stay engaged. My dealer suggested to take part #14 in the attached diagram. (drive shaft) and shave off 1/16" inch from the end (towards the sun gear, #18) to allow it to go in a bit deeper and not strip out. There is still plenty of clearance for freespool mode. One time I did strip these two parts, because I had the winch overloaded trying to pull a machine up a bad spot. As for the starter question, it is easy to get to and remove. I posted links a while back on where to download the service manuals for free. The brushes in the starter were worn and I was able to find a replacement online for about $35. Mike Warn Winch diagram.pdf

Here is a good guide for taking apart and cleaning a WARN winch. Mike Winch Cleaning Guide.pdf

Well made it home for Thanksgiving, and was able to get winch working for customer. Turned out to be solenoid or relay ( was a pain to install new relay ). When they just click 9 times out of 10 its the relay. The other quad is clicking when using starter. Customer opted to replace himself. We'll see how that plays out. keep you posted. The relay on this quad is on right side attached to outside of battery box. First must remove brake rear brake reservoir out of way. By the way it is a Warn winch standard with Arctic Cat. Very decent quads. Thanks for reading and replying.

It could be the relay, but if you see power to one terminal, it very likely is a problem in the brushes.Try powering the winch from jumper cables to bypass the solenoid..... If no go then , the problem is definitely internal to the winch motor.