Age : 25 Join date : 2012-12-24 Posts : 2951 Forum Rep : 71 Location : Lebanon County, PA
Subject: Harbor Freight Badlands 2500# Winch Switch Mod + Remote Reciever Removal Sun Dec 27, 2015 3:51 am
This is a how-to for adding in a switch as well as the removal of the leech in Badland ATV winches, also called the remote solenoid. You can add the switch in conjunction with the remote, or remove the remote and run only a switch.
MAKE NOTE: This tutorial covers both KEEPING and REMOVING the Remote Solenoid. Some steps are split into 2 paths, (a) and (b). If you are KEEPING the remote, follow the (a) steps. If you are REMOVING the remote, follow the (b) steps. This tutorial has pictures following the REMOVAL option, so some of the pictures may not be accurate.
You will need:
Solenoid Adaptation 2 - #10 Ring Terminal Connector 3 - Female Blade-type Connector 4in - 16ga Black Wire
External Wiring 3ft - 16ga Red Wire 3ft - 16ga White Wire 3ft - 16ga Yellow Wire
Switch 1 - ON MOMENTARY/OFF\ON MOMENTARY Switch, 3 Post
CountyLine (TSC) SKU#1831789 NAPA Auto Parts SKU#TG6566 Princess Auto SKU#8467193
1 - Switch Boot 3 - #10 Ring Terminal Connector
Tools Phillips Screwdriver Flat Screwdriver Wire Crimper/ Stripper Drill *1/4" or 5/16" Drill Bit *1/2" Drill Bit (for toggle-type switch) Lighter
*A step bit can be used, but be careful to not overbore the holes.
Consumables Gasket Sealer/ Silicone/ Liquid Electrical Tape Electrical Tape Zip ties Shrink Tubing (optional)
PROCESS Follow instructions as closely as possible to avoid damaging your parts. Failure to follow could result in damage to solenoid, winch, OR WORSE YET YOU.
Step 1: Place all tools and parts neatly around work area.
Step 2: Set solenoid box down with bottom cover facing up toward you. Situate to prevent wires from flipping it over while operating.
Step 3: Using a Phillips screwdriver, remove the 4 bottom screws from the cover and set off to a safe location along with the cover. Remove grommets from wires and set with screws and cover, as they disappear easily. MAKE NOTE OF LEAD WIRE LOCATION.
Step 4: Remove wiring from the box. Set box aside.
Step 5: Mark where the Yellow, Black, and White wires plug in. IT IS IMPERATIVE THEY GET PLUGGED INTO THEIR ORIGINAL POSTS. Unplug them.
Step 6: Using your Wire Stripper, cut the Blade-type Connectors from the wires coming from the Remote Solenoid (pictured on left). DO NOT CUT OFF THE #10 RING TERMINAL CONNECTOR ON THE BLACK WIRE.
IF KEEPING THE REMOTE (a)
Step 7a: Take your 6" long Yellow, White, andBlack leads and strip one end. Strip the ends off from the cloth-coated wires on the remote solenoid and CRIMP THE LIKE COLORS TOGETHER in a BLADE TYPE CONNECTOR. For example: Strip the end of your Yellow lead and Yellow remote solenoid wire. Twist ends together, insert into Blade-type Connector and crimp. Pull test to make sure connection isnt loose. If wire is loose, recrimp.
Step 8a: Take your 6" long Red lead and strip one ends. Crimp a #10 Ring Terminal Connector onto the end.
If properly done, you will not need the 4" Black lead.
IF REMOVING THE REMOTE (b)
Step 7b: Take your 6" long Yellow and White leads and strip one end. Crimp a Blade-type Connector onto each lead.
Step 8b: Take your 6" long Red lead and strip one end. Crimp a #10 Ring Terminal Connector onto the end.
Step 9b: Take your 4" long Black lead and strip both ends. Crimp a Blade-type Connector onto one end and a #10 Ring Terminal Connector onto the other end.
Step 10: Located under the Black terminal post on the winch solenoid, there are two ring posts. The top post has a Black lead, and the bottom a Red lead. Disconnect both. The top Black lead can be undone with a Phillips screwdriver and a Flat screwdriver or your Wire Stripper. Once bolt is removed, you can insert the Phillips screwdriver through the terminal and following the same method undo the Red lead.
Step 11: Attach the 6" Red lead to the Red lead on the solenoid. Replace the bolt and tighten well.
Step 12a: Re-attach the Black lead to the Black lead on the solenoid. Replace the bolt and tighten well.
Step 12b: Attach the 4" Black lead with the #10 Ring Terminal to the Black lead on the solenoid. Replace the bolt and tighten well.
Step 13b: Connect the Blade-type Connector on the 4" Black lead to the center terminal on the solenoid, directly above the Black lead.
Step 14: Connect your 6" Yellow lead to the top terminal (left in picture) and your 6" White lead to the bottom terminal (right in picture) on the Winch Solenoid.
Step 15: Using your Drill, locate a spot on the solenoid box to poke the wires through and slowly drill a hole through. I have found the spot pictured is the most ideal location. I used a 5/16" bit but a 1/4" bit with some wiggling will net a tighter and more secure fit.
Step 16: Poke your Red, Yellow and White leads through the hole. Snugly place the Winch Solenoid and Remote Solenoid (if retained) into the box. Move wires so they do not bulge out. Replace the grommets back onto the main leads and press them back into their original grooves in the solenoid box.
Step 17: Replace the bottom cover onto the solenoid box, making sure it sets flush on the box. Replace the screws and tighten snugly, being careful not to overtorque and strip the threads on the box. There is a small lip on the cover to aid in replacement. If there are any gaps, cracks, or bulges your box will not be waterproof and you must rearrange wires so it sits flush.
Step 18: Using your Gasket Sealer/ Silicone/ Liquid Electrical Tape, seal the hole with the Red, Yellow and White leads. Be sure to get sealant in between the wires. Allow to sit for an hour or two to let the sealant set.
Step 19: Once sealant is solidified enough, strip the ends of the Red, Yellow and White leads. Twist the ends of the wires and crimp on a watertight Male or Female Blade/Bullet-type Connector onto each. If you do not have watertight connectors, use a 2" long piece of shrink tubing to seal the ends. Shrink the connectors using a Lighter.
Step 20: Take your 3' Red, Yellow and White leads and strip the ends off of each. Crimp a watertight Male or Female Blade/Bullet-type Connector onto each end (the opposite style of the connector used in Step 19). Slide a 2" long piece of shrink tubing onto each lead (2 pieces if you do not have watertight connectors). Shrink the ends. Crimp a #10 Ring Terminal Connector onto the other end, and use a piece of shrink tubing to seal the end.
DO NOT CONNECT THE 3' LEADS TO THE SOLENOID BOX (yet).
Step 21: Find a location to mount your Switch. Drill a 1/2" hole (for toggle-type switch).
Step 22: Using the #10 Ring Terminal Connector end of your 3' leads, connect the;
White lead to the top post of the switch. This is OUT. Red lead to the center post of the switch. This is POWER. Yellow lead to the bottom post of the switch. This is IN.
Install the switch into the hole, ensuring the White lead is on TOP (toggle switches work in opposite. If OUT lead is up, when the switch is activated pushing up will activate the bottom terminal, bringing the cable IN. (If you get it wrong, either pull the switch out and rotate it or switch the Yellow and White leads around).
Step 23: Trace the leads to where the solenoid box will be mounted.
Step 24: Install the solenoid box. Connect the MOTOR leads to the winch.
Step 25: Trace the POWER leads to the battery. Connect the breaker connector (included with your winch) to the Red lead (REQUIRED). Wrap the breaker in Electrical Tape or coat with Sealant to prevent short circuiting.
Step 26: Connect leads to the battery (Red to +, Black to -). Connect switch leads to the solenoid box, being sure to match the color of the wire on the lead to the color of wire coming from the box.
Step 27: Tie your new winch and switch leads to the frame to prevent them from getting caught in brush.
Step 28: Test.
If you have any problems, comment below or contact me.
Alternatively, you can watch this video I did on the subject.