Replacing a Winch Cable

#warn #winch #winchcablereplacement #winchcable #warnwinch #atvwinch #suzukikingquad
****** BE SURE TO USE THE SAFETY BUTTON IN THE SMALL LOOP OF THE CABLE AT THE SPOOL WHEN YOU FIRST INSERT THE NEW CABLE INTO THE SPOOL ******
I broke the winch cable while using the snowplow this winter and the replacement came. It was sort of a pain that I could have made easier on myself by removing the fairlead, but overall it was not difficult.
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[@craig659]

Good video, the only suggestion i have is i would get a few wraps around the drum then hook the cable to a tree and use the wench to pull the cable in with your atv in neutral and light brake pressure to get a nice tight wrap around the drum.. I do reset my cable a few times a year and this is how i reset the cable...

[@GearTubeTV]

Good tip! Much better than the way I pulled weight to the ATV lol. Thank you for sharing because this is how we learn as a community!

[@josephrodriguez9895]

How did he fish out the broken cable? Be nice to know.

[@RocksNRuts4]

agreed!!

[@Trashpanda330]

You had Covid. Dec 2019. And you survived. WOW

[@GearTubeTV]

I never thought of it. Could be maybe... I remember being sick 2 or 3 times from December 2019-February 2020. 👍

[@-tee--bee-3230]

I have the same quad!! Suzuki makes a nice machine....

[@GearTubeTV]

They sure do!

[@easttex49m]

wish you would have shown how the cable actually comes out of the spool. mine has been in there since it was new (2011) and it does not want to just pull out

[@GearTubeTV]

Hey Joel, sorry for the late reply. Yeah I sort of messed up not filming a close up of how it comes out of the spool. You have to back off the pressure where it comes into the spool. To do that I used a flat screwdriver and hammer. I put the screwdriver into the hole in the spool opposite of where the cable enters and pounded the cable out. Think of a tunnel through the spool and a loop of cable gets pushed into one side of the tunnel. Put the screwdriver into the open end of the tunnel and hammer the loop of cable back out. Hope you got it figured out in the mean time, or if not hopefully this guidance helps a little better.

[@canamrider7195]

Why not just repair what is left of the cable? Wasteful to replace 50 feet cause you broke a few inches, or even a few feet.

[@GearTubeTV]

Very valid point! It would be cheaper and less wasteful. But, I don't mind spending the money and buying a new cable. In my opinion, they are not that expensive and for the "average Joe," easier to replace the whole thing versus cable repair. However, yes, you are correct in saying the cable is still useable and could just have a new loop crimped from the remaining good cable.

[@markg.2501]

5:02 .....So much for the warning about always wearing gloves when handling winch cable. Other than that.......A fine presentation.

[@GearTubeTV]

BUSTED! lol, it's funny how you don't even realize you break your own safety rules. 👍🏻

[@markg.2501]

@@GearTubeTV Taken like a true champion....Well Done Sir....Well Done Indeed!

[@larrylivingston9598]

Mark G. He says to wear gloves and even shows the ones he uses.

[@markg.2501]

@@larrylivingston9598 And then there's the part where he reply's to my comment ... "GearTube TV 9 months ago BUSTED! lol, it's funny how you don't even realize you break your own safety rules. 👍🏻 ".....(also see above). So, There's that.

[@sniperdog15]

Yeah so how’d you get it out??

[@GearTubeTV]

I took a large regular head screwdriver and placed it against the cable where it goes through the spool. Hit a couple of times with a hammer to push the cable back, which loosened the part of the cable where it loops around the "button." Then, the button falls out and you can pull the cable through the spool - then it's out.

[@FullsendOffroad]

wish I watched this earlier. think i busted a vein in my pinkie pulling out the winch manually because of the little threads of wire.

[@scottwinslow8772]

thanks for the vid it was very helpful

[@GearTubeTV]

Glad it helped someone out!! 👍🏻👍🏻

[@jrey7078]

Thanks for not zooming in on the winch spool and showing us how the cable attaches and how the first couple layers of cable lay on the winch when re-spooling. I like the mystery 👎

[@GearTubeTV]

Unfortunately I don't think of these things while doing the video, and once I finish up and edit it's too late to go back and film it again. I will say that if you are replacing the winch cable, you will see the hole in the drum where the cable passes through and makes a loop to secure it to the drum. As far as layering the cable, it's just like a garden hose on a hose reel - you want the first layer to lay tight against the drum with each wrap tight against the previous wrap. Once you have the first layer done, you do repeat it for each layer. This ensures you do not have a build up of cable on one side of the drum versus the other - again, think garden hose on a hose reel. I hope this helps solve the mystery for you, sorry I didn't get it in the video.

[@jrey7078]

GearTube TV - I get it thanks for the response. My comment was more for fun than an explanation. I often talk about making a KZbin video of my fixes but I talk myself out of it because filming is too damn hard especially if working by yourself. Take care

[@oneate5804]

I can't get the cable to come off the drum no matter how hard I hit the cable to try and free it from the button. Please help, i cannot find any help anywhere on the internet.

[@GearTubeTV]

I understand the frustration... The only way I know of to get the cable off the drum is to use a screwdriver (phillips head) and jam it into the hole in the drum where the cable enters. Hit it with a heavy hammer (mini sledge hammer). That should push it back through the drum and provide slack for that loop with the button. If the cable has been on the winch for an extended period of time, you might need some penetrating oil due to the possibility of the cable being rusted fast to the drum where it passes through the drum. It wouldn't hurt to spray some into that hole in the drum anyway if your cable has been on a long time. I know it isn't much help, but that is honestly the only way I know how to do it. Keep your chin up and keep working at it.

[@RocksNRuts4]

sane here i used a crimp

[@oneate5804]

@RocksNRuts4 I ended up cutting it and buying a new cable if I recall. I'm not too sure it was a while ago.

[@RocksNRuts4]

right but how did u attach to drum?@@oneate5804

[@kevinp5004]

Lol 50’ for a 2” lift for your plow. Makes sense

[@kevinp5004]

1 or 2 Crosby clips would suffice. Also there’s now snow in your video what are you plowing?

[@GearTubeTV]

😂👍

[@dreamlookautodetailingauto3353]

You said always safety first, but yet you didn't didn't use the red safety strap & didn't install the safety button on the cable before winding it up? These items are given for safety precautions...

[@GearTubeTV]

Some may call the red strap a safety strap, others call it a hook strap. It is not required to use the red strap, and, of course, there are no "requirements" on how to use a winch. If you wear decent gloves, you can grab the hook and pull the cable out just fine. But if you are actually going to touch the cable, you should wear gloves. With that said, this was not a safety video about winching and was not intended to discuss all safety aspects of winch use. There are many videos discussing winch safety and use. The video was about replacing the winch cable with some words of caution when handling the cable itself due to the metal barbs. With regard to the button - yep it should be in there. You're correct on that. And I will be more than happy to put a notice in the box below the video about the button. But, as I said in the video I personally chose not to use the button. It's a personal choice. My ATV is only used for snow plowing and an occasional trail ride, and the winch so far has only been used for snow plowing. In 3 years I've put less than 150 miles on it; therefore I personally am not concerned about the winch cable without the safety button. Snow plowing maybe uses 3 to 4 feet (with the pulley system) of cable from the spool and it's a 50 foot cable. I do appreciate your comment, don't get me wrong. And I appreciate you bringing up the safety button.

[@russjames556]

You should never grab the winch cable that close to the winch itself while running the winch...NEVER! waste of money and time...could have fixed in ten minutes by just putting a new cable clamp or if you have a crimper. the rest of the cable looked good...? I would only change the cable if it is all torn up. also, here's a tip...always carry a good ratchet strap if you're plowing, in case the cable breaks, you have a way to lift and hold your plow up until you get back.

[@GearTubeTV]

Thanks for the comment. To some a waste of time and money. To me a learning experience and enough youtube ad revenue to pay for the cable 🤷🏼‍♂️. Honestly, if I was penny pinching to the point I could not afford a replacement cable I probably shouldn't even have an ATV to begin with. And good tip as far as the ratchet strap. Fortunately I only plow my driveway which at most is 50' from my garage. 👍🏻

[@greglebeau9477]

Wow, you mention for safety to wear gloves when handling winch cable. You just pulled the cable off the spool without wearing gloves. Guess old phrase "Do as I say Not as I do " .

[@GearTubeTV]

Thanks Greg, you're the 3rd person to point that out here in the comments 😂... I messed up and there's no denying it. Fortunately I did not catch any wire barbs to the hand, but yes it is best practice to wear gloves for your personal safety. 👍

[@dan20675]

Not helpful to refer to something as being a pain in the ass and not show how you did it. Specifically, getting old cable detached

[@GearTubeTV]

Yes in my early years of making KZbin videos I struggled to show the best camera angles and get great footage. I also struggled with how to explain things. On the drum the cable passes through a hole that goes straight through the drum. On the other side the free end is bent around what is called a "button" and looks like a small circular solid button. The free end of the cable and button are then pulled tightly back into the drum so the cable and button are tight inside the drum. To remove the broken cable, take a small pry bar or thick regular head screwdriver and hammer the screwdriver or pry bar into the drum to push that button and free end of the cable out of the back of the drum. Don't lose the button if you don't have a replacement. That's how I did it.

[@GearTubeTV]

Watch at 5:00 - 7:00 and I explain it in the video.