[Sport4x4]

I’ve been snow plowing quite a bit the last few days and I have a intermittent issue with my winch pulling in to raise the plow. This really started last winter when plowing.
sometimes when I push the switch for “in” nothing happens and I push it repeatedly and nothing happens until I push the rocker switch to “out” a few times then “in” and all is fine again. Happens usually twice during an hour of plowing. I’m thinking it’s either the rocker switch or the solenoid. Was wondering what the group here would try first? Or could it be something else I haven’t thought of?

 

[cactus]

Next time it's not working pop the switch out and bridge it or the solenoid, if it works it's the switch. It's most likely the switch as I don't think they are very well made. Are you running through a relay?

 

[Sport4x4]

Well I assumed I am running through a solenoid but it’s been 2 years since I installed it so I guess I should dig the instructions out and double check that.

 

[cactus]

Well I assumed I am running through a solenoid

Through a relay you mean?

 

[Sport4x4]

Through a relay you mean?

Yes. Probably thinking of the contactor

 

[Sport4x4]

Ok no solenoid just the contactor (which is a relay) I will probably order a new rocker switch to keep on hand.

 

[EZYMNY76]

Just now reading this but has your problem been fixed in the areas that were previously discussed? Only other slight possibility could be is your winch is either getting weak or it’s freezing up. You said it won’t reel in but will out then it’ll reel in after reeling out. So less resistance on the winch going out so it spins. Add the weight of of the plow and weight of the snow that might be hung on the plow and the added moisture on the winch just a wild guess that it could be freezing up.

 

[Sport4x4]

Just now reading this but has your problem been fixed in the areas that were previously discussed? Only other slight possibility could be is your winch is either getting weak or it’s freezing up. You said it won’t reel in but will out then it’ll reel in after reeling out. So less resistance on the winch going out so it spins. Add the weight of of the plow and weight of the snow that might be hung on the plow and the added moisture on the winch just a wild guess that it could be freezing up.

Thanks, I would agree except when this happens all I get is a click sound and there is no weight on the winch strap because I always lower the plow to the ground until there is slack in the line. Which still makes me think it’s the switch. I haven’t had a chance to get a new one yet.

 

[Sport4x4]

Well I haven’t replaced the switch yet and now I’m not sure that’s it. My KFI winch has been getting louder and louder with a high pitched screeching noise. Dealer said seals are probably bad and it can be taken apart and cleaned and greased. Was hoping to get to the end of winter before tearing it apart but plowing snow to this morning I noticed grease oozing out around the spool. So now I’m not sure I should wait. Just would hate to have it apart then not be able to get parts or something and get another big snowfall.
I did some searching here and found some old threads about how these KFI winches have issues. I always had Warn before and never had any issues with them. If this isn’t a easy fix I will be searching for one of those.
Anyone here have issues with there KFI? Or have recommendations? Brand etc?

 

[Sport4x4]

Well decided to tear winch down. It was full of water. Grease looked like mud. O-ring seal on the spool looks like a poor design to me for keeping water out since the spool spins on it all the time. All cleaned up and tested but spool not back in yet until I can find a new o-ring.

 

[Sport4x4]

 

[cactus]

What a mess! Yeah that o ring is a bad idea, motor looks good though so should work again with a clean up, fingers crossed! I think I'd be putting that winch back in with the used o ring (as long as it's not physically damaged), buying a decent brand winch for the shelf and running that one until it fails again, which it will, even with a new o ring in place.

 

[Ironhide.au]

Looks like the inside of my KFI Stealth from a few years back. Bravo on how good you got that mess cleaned up. RTV that sucker up. Cheers


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[Sport4x4]

What a mess! Yeah that o ring is a bad idea, motor looks good though so should work again with a clean up, fingers crossed! I think I'd be putting that winch back in with the used o ring (as long as it's not physically damaged), buying a decent brand winch for the shelf and running that one until it fails again, which it will, even with a new o ring in place.

I was going to do just that with old o-ring but it is too stretched out, won’t stay in the slot.
And Ironhide, I did just that (RTV) with all the other joints. But I’m pretty sure the water is getting in around the o-ring, this is the weakest point.
Like cactus said; I will probably run it till it fails again then replace with a new Warn. Too much of a pain in the butt to pull, clean and new o-ring every year or 2.
I wonder how other manufacturers seal the spool to keep water out?
Anyone have a different brand apart to know?

 

[Sport4x4]

Looks like the inside of my KFI Stealth from a few years back. Bravo on how good you got that mess cleaned up. RTV that sucker up. Cheers


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Are you still using your KFI stealth since you cleaned it up? (Mine is a stealth also)

 

[Ironhide.au]

Are you still using your KFI stealth since you cleaned it up? (Mine is a stealth also)

Cleaned it up, not sure how long I ran it again for, but it’s sitting on the shelf in my shed. I removed my winch due to inactivity. I never go riding alone and most of the other guys I ride with have winches in emergency. I ride with Maverick’s/Teryx’s/Rmax’s, when they get stuck I’m the one to pull them out. 31’’ outlaws and Elka Stage4’s give me 16”GC at the front 15.5”GC at the back and 18” on the side rails. Ground clearance and torque for the win. Cheers
In the future I would like to get a new winch, just waiting to get stuck.


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[Sport4x4]

Researching I only found one winch with a waterproof rating. The Warn Axon has a IP68 rating.

 

[cactus]

Researching I only found one winch with a waterproof rating. The Warn Axon has a IP68 rating.

And from what I can see none of the Warn winches have that dodgy O-ring setup, the only place water could get in looks like either side of the spool, and hopefully they run double lip seals there on the shaft.

 

[Sport4x4]

I got everything back together tonight after work. We had a ice storm here yesterday and lost power for 29 hours. Sunny and warmer today so after it was all back together I had 6” of sloppy slush to plow out of the driveway. Winch worked fine but not much quieter than before the tear down. No issues with the switch either. But if that starts acting up again I will try using the 6’ handheld switch to eliminate the switch or the contactor.

 

[trailcutter]

i cover my winch with a rubber mat and helps to keep the rain and snow out.