Bumper not fitting after mounting winch.

[Brian D.]

Just wondering if any one has run into issues with the bumper not fitting correctly when mounting a winch on a Sportsman? I used a Kimpex mounting plate for my machine and mounted a Runva winch. The trouble I am having is the heads of the bolts that mount the winch to the plate are stopping the bumper from coming up high enough so I can get the bolts in. Basically, I think I need to cut the flange where the Polaris cover snaps into on the bottom to make space for the bolt heads. Here are a few pics, what do you think? Have I made an error mounting something?

 

[camoJoe]

shorter bolts and/or less washers , would probably help for starters, my winch has hex bolts that threads into winch body with 1 locking washer. not sure if that will help your issue.

 

[neilsleder]

X2 on shorter bolts. You should never use a lock washer on a flat washer cause then you only locking the bolt to the flat washer, and not the bolt to the solid peace.


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[Brian D.]

I will take the flat washer out and see where that puts me. I was also considering cutting the mounting plate back from the front by 2-1/2" as it sticks way out past the bumper and there is lots of room on the back side of the winch to move it. If I do that, then the heads will clear no problem. Is there an advantage to having the winch mounted further out vs. moved back a bit?

 

[Bezzola]

Use carriage bolts

 

[ippielb]

Use carriage bolts

I agree with this, find the round ribbed carriage bolts they use for studs on cars.

 

[Brian D.]

Thanks guys. I took the lock washers off and it gave it just enough clearance to get the bumper on. I also found that if I were to cut the mounting plate back, you wouldn't be able to get at the knob on the side of the winch to put it into free spool.