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KFI Assault ASPR-50 Operator's Manual

Synthetic cable utv winch kit 5,000 lb. (2268 kg)
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READ AND SAVE THIS MANUAL.
This manual contains important safety
precautions which should be read and
understood before operating the product.
Failure to do so could result in serious
injury. This manual should remain with the
product. Specifications, descriptions, and illustrations
in this manual are as accurate as known at the time of
publication, but are subject to change without notice.
Made in China - REV 20250224
ASSAULT
SYNTHETIC CABLE
UTV WINCH KIT
#ASPR-50
MODEL
5,000 LB. (2268 KG)
Support:
KFI Products - Kappers Fabricating, Inc., Spring Valley, MN USA
SERIES
SERIAL NO. LABEL
or visit
www.kfiproducts.com

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Summary of Contents for KFI Assault ASPR-50

  • Page 1 Specifications, descriptions, and illustrations in this manual are as accurate as known at the time of or visit publication, but are subject to change without notice. www.kfiproducts.com Made in China - REV 20250224 KFI Products - Kappers Fabricating, Inc., Spring Valley, MN USA...

  • Page 2: Table Of Contents

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH TABLE Of CONTENTS TABLE OF CONTENTS Maintenance ......... 14 Introduction ........1 Motor ............14 Accessories ..........1 Lubrication ..........14 This Manual ..........1 Safety Definitions ......1 Synthetic Cable Inspection .......14 Important Safety Instructions ..2 Cable Assembly Replacement ....15 Controls and Features .....

  • Page 3: Introduction

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INTRODUCTION INTRODUCTION SAFETY DEFINITIONS Congratulations on your purchase of a KFI winch. KFI The purpose of safety symbols is to attract your researches and develops winches to strict specifications. attention to possible dangers. The safety symbols, and...

  • Page 4: Important Safety Instructions

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH IMPORTANT SAfETy INSTRUCTIONS IMPORTANT SAFETY WARNING Pull only on area of the vehicle as specified by the vehicle manufacturer. INSTRUCTIONS WARNING Cancer and Reproductive Harm - WARNING Do not use the winch to secure or www.P65Warnings.ca.gov hold a vehicle for a long period of time.
  • Page 5 MODEL #ASPR-50 – 5,000LB (2268KG) WINCH IMPORTANT SAfETy INSTRUCTIONS WARNING CAUTION When re-spooling the cable, ensure If the motor stalls, do not maintain that the cable spools in the under-wind position with power to the winch. the cable entering the drum from the bottom, not Electric winches are designed and made for the top.

  • Page 6: Controls And Features

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH CONTROLS AND fEATURES CONTROLS AND FEATURES Read this operator’s manual before operating your winch. Familiarize yourself with the location and function of the control features. Save this manual for future reference. Winch Kit 1. Motor – 1.22 HP 12V DC motor provides power to 7.

  • Page 7: Installation

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INSTALLATION INSTALLATION (Located behind bumper) This KFI 5,000 lb Plug & Play winch assembly is designed to be a direct fit up to the specific UTV Models specified in our online application chart. Disconnect the Battery Start by making sure that the vehicle is on a level surface, shifted into park, and turned off.

  • Page 8: Install The Roller Fairlead

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INSTALLATION Fasten (2) zip ties [E] to upper mount plate flange orientation; place Carriage Bolt heads to the outside as shown to secure power harness. (winch side) and nut inside the frame. Do not fully tighten.

  • Page 9: Wiring - Route Power Harness

    Wiring - Route Power Harness NOTICE WIRING INSTRUCTIONS FOR SPECIFIC 2018+ MODEL VEHICLES ONLY. Older models may require battery extension kit KFI part #ASPR-EXT. Follow additional instructions with kit. WARNING Failure to follow specific wiring instructions may result in damage to your wiring system or equipment.

  • Page 10: Wiring - Install Switch Harness

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INSTALLATION 20. Gain access to the center wiring grommet [P] (see OEM Busbar Figure 12) by pulling out two plastic rivets [N] Neg (-) (Figure 11) and removing the plastic center section. Ground wire Wiring from the Switch Harness is routed from the dashboard through the wiring grommet [P], into the front compartment that is shown in (Figure 9).

  • Page 11: Corded Hand Remote (Optional)

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INSTALLATION NOTICE MEASURE the available knockout size, if the blank size does not match diagram in Figure 14, then drill holes and cut plastic to match the recommended knockout size. 23. Route the Switch Harness thru the dash knockout, pulling Switch Harness connectors into the center wiring grommet [P] and into the front compartment.

  • Page 12: Completing The Install - Final Steps

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH INSTALLATION Completing the Install - Final Steps 31. If using the Hand Remote Socket, be certain to 28. Connect the Power Harness to the OEM Busbar [M] connect the Red, ignition fed, +12V terminals [T]. (Figure 17).

  • Page 13: General Tips For Safe Operation

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH OPERATION General Tips for Safe Operation Self Recovery Your ASPR-50 winch is rated at 5,000 lbs. capacity in Locate a suitable anchor such as a strong tree trunk or first layer (max) when spooling the first cable layer on boulder.

  • Page 14: Winching Techniques

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH OPERATION Winching Techniques 15. The vehicle to be winched should be placed in Take time to assess your situation and plan your neutral and the parking brake released. Only release pull. the loads to the winch. This can damage the winch, Put on gloves to protect your hands.

  • Page 15: Synthetic Cable Usage

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH OPERATION Synthetic Cable Usage NOTICE Winch damage such as stripped gears, broken housings and bent or damaged parts Exercising proper care to prolong the usable life of a caused by exceeding your plow’s lift height are not Synthetic Cable is your responsibility.

  • Page 16: Maintenance

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH MAINTENANCE MAINTENANCE Synthetic Cable Inspection The owner/operator is responsible for all periodic maintenance. Periodically, inspect the synthetic cable for wear. When Complete all scheduled maintenance in a timely manner. new, it will have a smooth finish (see Figure A). Correct any issue before operating the winch.

  • Page 17: Cable Assembly Replacement

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH MAINTENANCE Cable Assembly Replacement It is recommended that any modifications be performed by a manufacturer’s authorized repair facility, and that only manufacturer-supplied parts be used (D) Compressed Rotate the clutch cap to the “Release” position. Look for powdered fiber or abrasion (signs of internal Extend Cable Assembly to its full length.

  • Page 18: Specifications

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH SPECIfICATIONS SPECIFICATIONS Performance: Rated Pull ......... 5,000 lb (2268 kg) Mounting Bolt Pattern ............6.6 in. x 3.00 in. (16.8 cm x 7.6 cm) Gear Reduction Ratio ..........180:1 Overall Dimensions ............Motor ....Permanent Magnet, 1.22 HP (DC 12V) 15.63 in.

  • Page 19: Parts Diagram

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH SPECIfICATIONS Parts Diagram 63.3 63.2 63.1 47 48 46 63.4 63.5...

  • Page 20: Parts List

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH SPECIfICATIONS Parts List Part Number Description Part Number Description MOTOR-AS50 Motor Assembly 43 HW-0008-B Bolt M8 x 25 HW-0023-B Screw M5 x 16 Socket 44 HW-0009-B Washer M8 Lock WP-0026 Coupling, I 45 HW-0016-B Washer M8 WP-0055 Coupling, II...

  • Page 21: Troubleshooting

    Hand tighten nuts on all cable connections. Contactor makes a click sound. Motor Issue Contact KFI Technical Support Allow to drain and dry. Run in short burst with Water has entered motor load until completely dry. Brake Spring installed backwards Contact KFI Technical Support.

  • Page 22: Warranty

    Kappers Fabricating Inc. (KFI) will register this warranty upon receipt of your Warranty Registration Card and Other Exclusions a copy of your sales receipt from one of KFI’s resale locations as proof of purchase. Please submit your – The winch cable or synthetic cable.

  • Page 23: Contact Information

    MODEL #ASPR-50 – 5,000LB (2268KG) WINCH Contact Information Address KFI Products Winch Customer Service P .O. BOX 32 721 SATA DRIVE SPRING VALLEY, MN 55975 Corporate KAPPERS FABRICATING, INC. P .O. BOX 32 1015 INDUSTRIAL DR. SPRING VALLEY, MN 55975...
  • Page 24 1-877-346-2050 KFI PRODUCTS P .O. BOX 32 721 SATA DRIVE SPRING VALLEY, MN 55975 WWW.KFIPRODUCTS.COM CORPORATE OFFICE: KAPPERS FABRICATING, INC. P .O. BOX 32 1015 INDUSTRIAL DR. SPRING VALLEY, MN 55975 MADE IN CHINA ©2025 KAPPERS FABRICATING, INC.