You can change it out with the winch in place. It's a pretty easy process. Just pay attention as you are removing it.

Here's what it will look like without a cable in it. Where you see that hole there is one on the opposite side. The cable end is fed through the opposite side and comes out of the hole you see. Stuff the end back in the hole you see creating a small loop. You should have a small metal wedge. Place then in the loop and pull the cable tight from the back side. The line should be secure. Now wind up your winch cable. Best to do that by using the machines weight. Tie a tow strap around a tree and connect the winch cable to it. Throw the machine in neutral and have someone sit in the RZR and press the "in" button. Meanwhile you walk with the machine and guide the cable/line back onto the drum neatly.

Once you pull it apart you'll understand what I described! Good luck!

 

Thanks, I was able to get it without taking the winch off.[]

 

I don't think you can secure the synthetic cable the same way as the steel. Too slippery & compressible. Warn told me to lay the end across the drum and wind the rope across it. I'm not crazy about it not being secured but I guess you're not suppose to fully unwind the winch anyway. I marked the rope with a stripe of paint where it was down to the first layer. The Amsteel cable I bought came with a copper lug crimped on the end but there was no place to screw it and it would have left a big bulge on the spool anyway.

I'm open to other ideas...I'm going to replace the steel cable on the Ramsey as soon as it arrives.

 

I cut the copper end off and used some electrical tape on the end. I then did as I described above and really can't see it pulling through when reuse that little metal wedge. As long as you have 4 to 5 wraps around the drum you'd be fine. I've never been in a situation where I needed more than 20-25 feet tops anyone. I also have an 8ft Amsteel blue I use in the winter for plowing. The upward pull puts a ton of stress on the winch. I broke my steel cables loop while plowing. Never had a problem with the Amsteel. Even with only 8ft of rope.

 

I'm sure you're right--I was just saying you can't totally rely on the lug or the loop to hold your rig if you play out all the rope.
When I called Warn it was to ask if I should just tie the end to the spool but they recommended against it due to the hump the knot would make.

 

Wonder how they secure their synthetic line that comes on some of the winches?

 

I also cut off the crimp and taped the end. Then slipped the end through the hole on the drum and tied a knot. One thing about getting rid of the wire rope. Once you use the other you are spoiled.

 

Should have added to the first post. On the bigger winches, not the ATV line, the cable end has a crimp and has a screw that goes to the side of the drum. Same for cable and rope.

 

have any of you changed the cable on a 4.0? i'm having trouble getting the old cable loose from the drum. the cable is looped inside the drum and there is about 1/4 inch of the end of the cable sticking out of the drum. i can't seem to get any thing in between the drum and where the cable is looped back through to pry it loose. any suggestions?

 

You should be able to take a small screwdriver & pry the loop out of the slot. Or stick it through the forward hole & poke the wedge & loop out the back.
The wedge (or pill) might drop out so don't lose it.

 

To secure synthetic rope to your winch, put the end through the hole in the drum, then tie a surgeons knot (just an overhand knot that you push the tag end though the loop an extra time) in the end. pull tight by hand and wind onto the drum.