Wiring a Champion winch in an ATV requires weatherproof connections, the proper gauge wiring relative to the maximum amperage draw and a good fused circuit. When using a small battery, resistance in the wiring reduces the available voltage and amperage for the winch and accelerates the drain on the battery.
Connect the wires from the winch to the contact box, or to the battery if no box is available. Start by running two lengths of 6-gauge wire from the winch up through the left side fenderwell and to the contact box designed for this purpose. Measure one wire first by clamping it at the winch with a few inches to spare. Unroll the wire as if installing it behind the winch, and down the inside the left fender against the rail and up to the contact box or battery if necessary. Cut a second piece of wire the same length.
Slip a 4-inch piece of shrink-wrap over the end of both wires at the winch. Connect the red and black wires on the winch to the two wires you just cut, using butt connectors to attach the wires together. Crimp them with the wire crimpers.
Slide the shrink-wrap down over the wire butt connector and center it. Heat the shrink-wrap with a lighter to shrink it and make a watertight seal. Connect the two wires to the contact box or battery in the exact same way. (Make sure that the wire attached to the red wire on the winch is attached to the red wire or the positive wire in the box or on the battery, and the ground or black wire to the black wire or black negative terminal on the battery.)
Tie up the two wires using wire ties, every 3 inches from the winch to the contact box. Tie the wires to the frame or any place possible that will keep them secure. Plug the remote switch into the winch, and attach it to the handlebars for ease of use so the ATV can be steered while operating the winch. Wire tie the remote switch wires to keep them secured to the ATV.
