KFI Assault ASP-35 Owner's Manual And Operating Instructions

3500 lb. atv/utv winch

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Model #ASP-35
Revision Date 2019-04-01
Owner's Manual and Operating Instructions
3500 lb.
ATV/UTV WINCH

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Summary of Contents for KFI Assault ASP-35

  • Page 1 Model #ASP-35 Revision Date 2019-04-01 Owner’s Manual and Operating Instructions 3500 lb. ATV/UTV WINCH...
  • Page 3: Table Of Contents

    Table of Contents Introduction��������������������������������������������������������������������������������� 1 Accessories �������������������������������������������������������������������������������������������������������1 This Booklet �����������������������������������������������������������������������������������������������������1 Introduction��������������������������������������������������������������������������������� 1 ManualConventions������������������������������������������������������������������� 2 SafetyRules���������������������������������������������������������������������������������� 3 ControlsandFeatures����������������������������������������������������������������� 5 Winch ���������������������������������������������������������������������������������������������������������������5 Installation � ����������������������������������������������������������������������������������� 6 Step 1-ATV Install Preparation ������������������������������������������������������������������������6 Step 2-Winch Assembly Preparation ����������������������������������������������������������������7 Step 3-Install Winch Assembly �����������������������������������������������������������������������8 Step 4-Handlebar Remote Install ����������������������������������������������������������������������9 Step 5-Reinstall ������������������������������������������������������������������������������������������������9 Operation �...
  • Page 5: Introduction

    Introduction Introduction This Booklet Congratulations on your purchase of a KFI winch. Every effort has been made to ensure the KFI researches and develops winches to strict accuracy and completeness of the information in specifications. With proper use and maintenance, this manual.
  • Page 6: ManualConventions

    Manual Conventions Manual Conventions CAUTION This manual uses the following symbols to CAUTION indicates a potentially hazardous help differentiate between different kinds of situation which, if not avoided, may result in information. The safety symbol is used with a key minor or moderate injury.
  • Page 7: SafetyRules

    Manual Conventions Safety Rules WARNING WARNING Read this manual thoroughly before operating Do not move the vehicle to pull a load (towing) your winch. Failure to follow instructions could on the winch cable. This could result in cable result in serious injury or death. breakage.
  • Page 8 Safety Rules CAUTION WARNING Do not wrap the cable around any object and Batteries contain acid and produce explosive hook it back onto itself. gases. Keep sparks, flames and cigarettes away from CAUTION batteries at all times. Wear safety glasses and protect the eyes at all times.
  • Page 9: ControlsAndFeatures

    Controls and Features Read this owner’s manual before operating your winch. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Winch Motor (1): 1.15 HP 12V DC motor provides power Planetary Gear System (7): The reduction gears to the planetary gear mechanism.
  • Page 10: Installation

    Installation Installation “Figure 1” This KFI 3,500 lb Plug & Play winch assembly is designed to be a direct fit up to the specific ATV Models from our online application chart. Step 1-ATV Install Preparation WARNING Before you start to install this winch, disconnect the vehicle ground and positive leads from the battery.
  • Page 11: Step 2-Winch Assembly Preparation

    Installation Step 2-Winch Assembly Preparation This winch assembly comes pre-assembled and ready to go for the 850 and 1000 Polaris ATV’s. If you have the 850 or 1000 please skip this step. If you have the ETX, 450 or 570 ATV please continue with this step.
  • Page 12: Step 3-Install Winch Assembly

    Installation CAUTION Never route electrical cables across any sharp edges, through or near moving parts, or near parts that become hot. Routing of the battery wires will be on the passenger side of the vehicle, just behind the radiator. Stay clear of cooling fan and use zip ties to secure wire in place.
  • Page 13: Step 4-Handlebar Remote Install

    Installation Step 4-Handlebar Remote Install Cut zip tie retaining handle bar wires [L]. Locate factory integrated harness connector and remove protective cap [M]. Mount the switch assembly [N] to handlebar location as shown. With the switch mounted, attach the switch plug [O] to the integrated plug [M], and install a new zip tie at location [L].
  • Page 14: Operation

    Operation Self Recovery General Tips for Safe Operation Locate a suitable anchor such as a strong tree Your ASP-35 winch is rated at 3,500 lbs. capac- trunk or boulder. Always use a sling as an anchor ity in first layer (max) when spooling the first rope point.
  • Page 15: Winching Techniques

    Operation Winching Techniques 15. The vehicle to be winched should be placed in neutral and the parking brake released. Only release the loads to the winch. This can damage the winch, cable and vehicle. Take time to assess your situation and plan your pull.
  • Page 16: Maintenance

    Maintenance Lubrication Maintenance All moving parts within the Electric Winch have The owner/operator is responsible for all periodic been lubricated using high temperature lithium maintenance. grease at the factory. No internal lubrication is WARNING required under normal conditions. If the winch is subjected to extreme conditions lubrication may be Never operate a damaged or defective winch.
  • Page 17: Asp-35Specifications

    ASP-35 Specifications Performance Specifications Rated Pull 3,500 lbs (1589 kg) Gear Reduction Ratio 180:1 Motor Permanent Magnet 1.15 HP/0.89kW (DC 12V) Drum Size 1.75” (D) x 3.19” (L) 44.5 mm (D) x 81.0 mm (L) Synthetic Cable 3/16” (D) x 50.0’ (L) 4.8 mm (D) x 15.24 m (L) (48 useable feet with five wraps on the winch drum)
  • Page 18: Model Winch Diagram

    ASP-35 Specifications Model Winch Diagram ASP-35...
  • Page 19: Winch Parts List

    ASP-35 Specifications Winch Parts List Part# Description Part# Description MOTOR-AS35 Motor Assembly AP-BAT-WIRE2 Battery Wire - Black 410018-B Bolt M5 x 16 AP-WIN-WIRE Winch Wires - Blue/Yellow 450001 Coupling, I AP-MR Mini Rocker Switch 450003A Coupling, II 250047-BF MR Mounting Angle 410001 Spring 250054-B...
  • Page 20: Troubleshooting

    Contactor Issue Refer to our contactor troubleshooting guide at www.kfiproducts.com under “Support” Call KFI Technical support Double check your winch wiring diagram to make sure all wires are correct. Wired Incorrectly Hand remote / Dash rocker wires need to always Contactor clicks but the be green to green and black to black.
  • Page 21: Warranty

    Kappers Fabricating Inc. (KFI) will register this warranty upon receipt of your Warranty Registration Card and a copy of your sales receipt from one of KFI’s resale locations as proof of purchase. Please submit your warranty registration and your proof of purchase within Fifteen (15) days of the date of purchase.
  • Page 22: Contact Information

    Your purchase of the product shall constitute your release and indemnity in favor of KFI and/or or its parent company, its shareholders, officers, directors and employees from any and all claims or injuries of every kind resulting from use or operation of the product, including costs and attorney’s fees...
  • Page 23: SyntheticCable

    Synthetic Cable DANGER Sharp edges and rough surfaces will shorten cable life. Inspect the cable and protective sleeve before use. Replace cable immediately if the cable has cut strands, fused or melted fibers, odd stiff sections, chemical contaminated, flat areas or lumps that cannot be eliminated after flexing the cable.
  • Page 24 1-877-346-2050 KFI Products P.O. Box 32 721 Sata Drive Spring Valley, MN 55975 www.kfiproducts.com Made in China ©2018 Kappers Fabricating Inc. Corporate Office: Kappers Fabricating Inc. P.O. Box 32 1015 Industrial Drive Spring Valley, MN 55975 USA...

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