Corrective Action:

Move clutch lever to freewheel position and then let it gently return to the engaged position using spring pressure only. DO NOT FORCE THE LEVER TO THE STOP. Remove the two small phillips head screws and the clutch lever and examine the position of the spring keeper lug in relation to the stop in the side of the housing. If the lug is touching or very close to the stop (see photo), then clutch is out of adjustment. There are two possible causes which need to be investigated. The thrust bearings could be worn out or the clutch pad could be damaged. To investigate these possibilities, remove the winch cover and disassemble the clutch mechanism as follows. With a flat blade screwdriver pry the end of the clutch spring from the hole in the winch base. The spring tension is quite high and the spring will snap violently when it comes free, so be careful to keep your hands and other body parts away. Rotate the plastic O-ring so the the cut out portions align with the pegs on the spring keeper. The O-ring can then be expanded with a pencil, pocket knife or similar tool and the spring keeper can be lifted free from the clutch nut. Thread the clutch nut off of the stud (it is a left hand thread). You will then see the outer thrust bearing with a hardened bearing race (flat washer) on both sides. Lift both of the gears off of the stud and notice that there is a small spring washer between them. The inner thrust bearing and two races can then be removed. There may be additional spacer washers on the stud and these should remain on the stud. Check the condition of both of the thrust bearings and the races and replace if noticeably worn, dry or burned. Order and install thrust bearing kit 5703194, which includes two bearings and four races. Examine the condition of the clutch pad. This is bonded to the large gear in newer models or bonded to the flange of the small gear in older models. If there are portions of the clutch pad missing or torn away, or any other significant damage to the pad, a replacement is necessary. If the clutch pad in your winch is bonded to the large gear, you can replace just that gear. Order 120 tooth gear assembly 306102 for SA5000/SA7000 models or 84 tooth gear assembly 306101 for SA9000/SA12000 models. If the clutch pad in your winch is bonded to the clutch gear flange it will be necessary to order clutch gear assembly 306100 in addition to one of the above gears. Reassemble and adjust the clutch by the following procedure. Place one of the thrust bearings (with a race on each side) on the clutch stud. Next install the clutch gear and the spring washer oriented as shown in the photo on the stud followed by the large gear turned with the pad facing the clutch gear. Install the outer thrust bearing (with a race on each side) and then install the clutch nut (left hand thread). Use the plastic spring keeper to tighten the nut by hand only. Then insert one leg of the clutch spring into the hole in the spring keeper. Note that on SA5000/SA7000 models the legs of the clutch spring are not equal length. The longer leg attaches to the spring keeper. On SA9000/SA12000 models both legs are the same length and it makes no difference which one attaches to the spring keeper. Position the keeper on the clutch nut so that the lug is positioned at the 2:30 o’clock position (see photo). Reinstall the plastic O-ring and rotate it slightly to lock the spring keeper in place on the clutch nut. Grip the free end of the spring with pliers or vise grips and insert the end into the hole in the winch base. This is challenging because the spring tension is quite high. Make sure the end goes all the way into the hole. Slip the clutch lever onto to the spring keeper and move the lever to the freewheel position and gently allow it to return to the engaged position using the force of the spring only. DO NOT FORCIBLY MOVE THE LEVER PAST WHERE THE SPRING TAKES IT. Remove the lever and check the position of the lug on the spring keeper. It should be at approximately the 2:30 o’clock position (see photo). If not, without moving the position of the clutch nut, disassemble the spring, O-ring and spring keeper and reposition the keeper on the nut so that the lug is at 2:30 o’clock and reassemble. Recheck to confirm that the spring keeper stops in approximately the same position when the lever is moved to freewheel and allowed to return to engaged using spring pressure only. Note that if the lug on the spring keeper is set too high, the clutch may slip under heavy load. If it is set too low the clutch will be too tight and will create excess strain on the motor and excess load and heat on the thrust bearings. Our clutch adjustment video may be helpful.

Corrective Action:

Remove the winch cover. Run the winch and observe which parts are turning and which are not. This should make the source of the problem obvious. Refer to the owner’s manual or website for the necessary repair parts.