UTV Winch Wiring Question

[frankd]

So I bought a new (to me) Polaris rzr and I'm making a few changes to it. One of them is rewiring the winch because I don't like the way it was set up.

The current wiring is 6 gauge. I'm re-using the wiring from the winch to the contactor but need to replace the wiring from the contactor to the battery since the current wire is too short. I went to Lowes and picked up some stranded wire (see link below) and I'm not sure if the wire I bought is appropriate. When I compare the Lowes wire to the existing wire I can see that the insulation on the Lowes ware is kind of plastic and thin vs the thick rubber on the existing wire. Also, the copper strands on the Lowes wire are much thicker but I imagine the only difference that will make is that the Lowes wire won't be as flexible.

The description says its resistant to moisture, gasoline, and oil. And thats its ok for wet or dry locations. Also rated for 190 degrees... So I'm thinking I should be fine but figured I'd see if there's anyone out there that has experience with this sort of thing.

https://www.lowes.com/pd/Southwire-SIMpull-6-AWG-Stranded-Black-Copper-THHN-Wire-By-the-Foot/3129547

 

[JeepJohn62]

I would explore wire at a marine supply store. More $$, but likely made for tougher environment. You only need a few feet. They usually offer a termination with heat shrink to seal out corrosion.

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[frankd]

I would explore wire at a marine supply store. More $$, but likely made for tougher environment. You only need a few feet. They usually offer a termination with heat shrink to seal out corrosion.

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Think an auto parts store can do the same thing? I'm not aware of any marine equipment stores by me....but I do live on an island so there must be some

 

[Bad Habit]

You probably bought buying wire (THHN/THWN) that will be very stiff and difficult to work with. You want something more akin to welding wire, much more flexible

 

[PapasDaLife]

You probably bought buying wire (THHN/THWN) that will be very stiff and difficult to work with. You want something more akin to welding wire, much more flexible

Agreed, welding wire is what you want. Amazon sells it. That's where I get mine. I do a lot of solar panel installs in rvs. So the more flexible works best.


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[MoonRise]

Yeah, your link is to THHN wire.

Perfectly 'good' wire, for wiring a house or similar.

Might be a bit stiff for wiring a vehicle. And the 'harder' plastic insulation is thinner than a 'thick' rubber-type insulation. It insulates the wire just fine, but has less margin for chafing or wear-through than a thicker type insulation.

As to the wire itself, that depends a lot on the length of the wiring and amperage draw of the device/application. Winches can draw a LOT of amps when used to pull a load.

Some possible other wire choices would be some battery cables (available at lots of places, like auto parts stores, Walmart, on line, etc) or welding cables (as mentioned, available at some places like Tractor Supply or welding supply stores and on line).

 

[like2wheel]

Think an auto parts store can do the same thing? I'm not aware of any marine equipment stores by me....but I do live on an island so there must be some

Yup.
A good one will have a roll they cut & sell by the foot.
Or you can buy a pre-made cable & cut if needed.

Or maybe go to a pick & pull with a pair of wire cutters



.

 

[JeepJohn62]

I will give you a good website reference called Polarwire.com. They are in Alaska and provide quality materials for extreme environments and marine equipment.

They have some good reference info and you may be able to find a local supplier with similar products.

I'm sure a local auto store will be able to get you going also. I recommend a good quality flexible wire for atv stuff. And make good quality terminations for reliability.
John

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[frankd]

Thanks for all the replies. Looks like I just wasted $20 on that lowes wire...lol. I'm sure I'll find some sort of future project where I need it.
I'm going to start with my local auto parts store since there's one nearby to see if they've got the wire.

 

[ant.foste]

You want SO, DLO, W, or SC cable. Take a look at wireandcableyourway.com. Legit place, I've used them a lot with excellent results.

 

[bwringer]

That THHN is too stiff and will not stand up to vibration. I don't know how much your UTV vibrates, probably not much, but that wire is not really intended for use in vehicles.

 

[Dustball]

I recommend ordering this in the length you need and the lug end you need (5/16"?)-
https://amzn.com/B01F2NEJUQ

 

[BD1]

Maybe check with Polaris and see what they have.

https://ranger.polaris.com/en-us/shop/accessories/


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[JeepJohn62]

Here's one idea from Amazon.

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[Noltz]

Welding wire is what we use on off-road vehicle winch setups. I used 4 gauge wire, crimped heavy copper terminals with a bench vice and then filled them with solder warmed up with a propane torch. Double wall heat shrink tube would give it a nice finished look. Never had an issue.

 

[HenryAZ]

I have used Battery Cables USA to purchase battery cables for my genset. They are fine stranded and flexible, and made to order the same day, shipped within one business day. They offer standard battery terminal ends, lug ends, and Anderson PowerPole connector ends. Their lug ends are available with 3/16", 1/4", 5/16", 3/8", or 1/2" holes. I am very pleased with their HD quality, and the connectors are all heat shrink wrapped. Lengths are 6"-72" by the inch, and 8ft-30ft by the foot.

 

[bwringer]

I have used Battery Cables USA to purchase battery cables for my genset. They are fine stranded and flexible, and made to order the same day, shipped within one business day. They offer standard battery terminal ends, lug ends, and Anderson PowerPole connector ends. Their lug ends are available with 3/16", 1/4", 5/16", 3/8", or 1/2" holes. I am very pleased with their HD quality, and the connectors are all heat shrink wrapped. Lengths are 6"-72" by the inch, and 8ft-30ft by the foot.

Thanks for that link!

I've made lots of motorcycle battery cables (vintage Suzukis usually use a Japanese wire gauge slightly larger than 8AWG, so I usually make them with 6AWG wire), but if I had known there was a place that could make them this dang cheap, I wouldn't have bothered to buy the materials and crimper.

Plus, it looks like they have a special wire with a much better dual layer jacket than welding cable specifically for battery cables. Nice!