P500 Winch wires too short?

[Chance135]

I began to install a new superwinch LT4000 UTV on my P500 and much to my surprise the included wires are far too short. the wires that route from the solenoid to the battery are both 6 feet long and it appears I need around 8 feet to make it. Am I doing something wrong here? Even the black wire that routes from the winch to the solenoid ran short by about two inches.

 

[Admin]

 

[trigger]

I began to install a new superwinch LT4000 UTV on my P500 and much to my surprise the included wires are far too short. the wires that route from the solenoid to the battery are both 6 feet long and it appears I need around 8 feet to make it. Am I doing something wrong here? Even the black wire that routes from the winch to the solenoid ran short by about two inches.

You routed under the floorboard and above the skid plate? Mounted solenoid somewhere near firewall?

 

[Chance135]

Yes. I followed the factory wiring harness that drops down the firewall and back along the frame rail that is located above the the skid plate. I mounted the solenoid in the factory location as well. Sorry, those are important details I left out of the original post.

 

[Montecresto]

Yes. I followed the factory wiring harness that drops down the firewall and back along the frame rail that is located above the the skid plate. I mounted the solenoid in the factory location as well. Sorry, those are important details I left out of the original post.

That's how I did mine and wires were long enough, but that was for Superwinch.

 

[trigger]

Yes. I followed the factory wiring harness that drops down the firewall and back along the frame rail that is located above the the skid plate. I mounted the solenoid in the factory location as well. Sorry, those are important details I left out of the original post.

Well, that sucks. I didn't have a lot of wire left over when I did mine but I did have enough to make it back to the battery box.
I guess you either have to buy some longer cables or mount a junction/power distribution somewhere. I mounted a power block in my toolbox that feeds all the accessories. Just had to feed that off the battery. Wouldn't be a bad idea if you plan on adding more electrical later. Just try to keep it high and dry.

 

[Montecresto]

Well, that sucks. I didn't have a lot of wire left over when I did mine but I did have enough to make it back to the battery box.
I guess you either have to buy some longer cables or mount a junction/power distribution somewhere. I mounted a power block in my toolbox that feeds all the accessories. Just had to feed that off the battery. Wouldn't be a bad idea if you plan on adding more electrical later. Just try to keep it high and dry.

How'd you do that trigger, drill a hole and come up through the bottom???

 

[Talen]

I began to install a new superwinch LT4000 UTV on my P500 and much to my surprise the included wires are far too short. the wires that route from the solenoid to the battery are both 6 feet long and it appears I need around 8 feet to make it. Am I doing something wrong here? Even the black wire that routes from the winch to the solenoid ran short by about two inches.

I had same problem. You can either move the solenoid or buy longer cable. I didnt want solenoids down low in constant water. So i used new cable i had from my car audio days. Was heavier gauge. I actually bolted the black and red together to make one long one. Then used the cable i had for the other. Its hard to find cable these days unless you order online. Luckily i had some

 

[trigger]

How'd you do that trigger, drill a hole and come up through the bottom???

Yeah, drilled a hole and used a bushing. Went with a huge bushing too, figuring it would be big enough for future accessories.
Last wires I pulled in were fitting a little snug.
Car audio shops are the best place to find cables. Cost more than the standard stuff at HD but that's because it's very flexible and easier to work with. Better copper too.

 

[pFive]

I have a 3k lb winch and while it does not use a solenoid the wires were too short. I purchased a set of cheap jumper cables and cut the ends off to get a decent gauge wire with a heavy jacket at a low cost.

 

[Montecresto]

Yeah, drilled a hole and used a bushing. Went with a huge bushing too, figuring it would be big enough for future accessories.
Last wires I pulled in were fitting a little snug.
Car audio shops are the best place to find cables. Cost more than the standard stuff at HD but that's because it's very flexible and easier to work with. Better copper too.

Cool, you mean like a rubber grommet, or other. I never thought about going to a car audio shop, I just ordered a spool off amazon, and soldered lugs on for my own custom length, and then shrink wrapped the connections.

 

[trigger]

Cool, you mean like a rubber grommet, or other. I never thought about going to a car audio shop, I just ordered a spool off amazon, and soldered lugs on for my own custom length, and then shrink wrapped the connections.

Electrical bushing. Steel nipple with thin nuts on each side, then a plastic nut on each side so as not to dig into the wire. About 1 1/2" around.

 

[Montecresto]

Electrical bushing. Steel nipple with thin nuts on each side, then a plastic nut on each side so as not to dig into the wire. About 1 1/2" around.

Ah yes, I know what you're referring to now.

 

[bigbore]

I began to install a new superwinch LT4000 UTV on my P500 and much to my surprise the included wires are far too short. the wires that route from the solenoid to the battery are both 6 feet long and it appears I need around 8 feet to make it. Am I doing something wrong here? Even the black wire that routes from the winch to the solenoid ran short by about two inches.

I bought new cable so I wouldn't have to worry about it.

Here is a link to my install if you are interested:

P500 - Obsessive winch install.

 

[Mudder]

Ran a 6 ga wire to the hood out of the battery cover box square hole behind the positive battery terminal and mounted a Bussman waterproof switchable breaker to the large diameter frame tube behind passenger. Out of the way but easy to get to. See red button in pic. Wire in split protector. Normally kept off.

 

[Montecresto]

Ran a 6 ga wire to the hood out of the battery cover box square hole behind the positive battery terminal and mounted a Bussman waterproof switchable breaker to the large diameter frame tube behind passenger. Out of the way but easy to get to. See red button in pic. Wire in split protector. Normally kept off.

View attachment 27422

That's a good enough spot for it!!

 

[monaco]

same problem with the same winch. I have 4ga 8' cables on order

how do you like the LT4000?