INSTALLATION & OWNER S MANUAL INSTALLATION INSTRUCTIONS KAWASAKI MULE 4000 CAB KIT (p/n: KAF40-005WA and KAF40-005BA) NOTE: Hard sided doors are sold separately. This manual is the property of the owner. Be sure to leave with the owner when installation is complete. Rev. F p. 1 of 7 p/n: IM-KAF40-005
ADDED WEIGHT Curtis Cabs, blades and general accessories add additional weight to the base vehicle. All Curtis accessory weights are listed in product brochures. Deduct the accessory's total weight from the vehicle's rated capacity and never exceed the vehicle's rated capacity including driver and passenger. Exposure to Carbon Monoxide can Cause illness, serious injury or death. Never operate vehicle if suspicious of Carbon Monoxide. Inspect exhaust system for leaks monthly. Leaks can result from loose connections, corrosion, cracks or other damage to the exhaust manifold. If leaks are found, repair or replace exhaust system. Do not use vehicle until repair or replacement is complete. CAB INSTALLATION BEFORE YOU START HELPFUL HINTS: A. Refer to parts diagram toward the back of this manual to help identify parts during the assembly process. B. To assist with the cab installation, leave all bolts loose for later adjustment unless otherwise specified. C. Read and understand all instructions before beginning. D. Plastic washers have been supplied to provide a weather seal under the heads of all exterior bolts. The plastic washer should be installed under each bolt head directly against the outside cab surface. Care should be taken not to over tighten the fasteners and damage the plastic washer. Also use steel washers as required. See diagram. E. Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variations. F. Use caution to avoid damaging the factory installed threaded inserts. Begin the bolt engagement by hand to guard against potential cross threading. TOOLS REQUIRED: Set of standard and metric sockets Set of standard and metric open end wrenches Drill 3/8" drill bit. Bar Clamp One Phillips Head Screwdriver One 3/8 Drive Ratchet One 3/16 Allen Wrench Utility Knife Tape Measure p. 2 of 7
VEHICLE PREP: NOTE: HEAVY DUTY FRONT SUSPENSION SPRINGS (p/n: 92144-1919) ARE REQUIRED WHEN INSTALLING THIS CAB. INFLATE FRONT TIRES TO 1.0 kg/cm2 or 14.2 PSI AND MAINTAIN AT THIS PRESSURE. A. On model years with retractable seat belts, flip the passenger s side seat belt so that it no longer protrudes outboard of the ROPS. That will give clearance away from the cab frame once it s installed. Fig. A1 shows the original orientation and Fig. A2 shows it flipped for clearance. Tighten the bolt back to the original OEM torque of 33 ft.-lbs. (or 44.5 N-m). B. Per fig. B, remove bolts from between front and rear ROPS. Remove nuts and bolts from top of rear screen. Save all hardware for later use. C. Per fig. C, loosen all nuts attaching seat back to vehicle. Remove the two upper nuts but leave the bottom nuts attached. STEP 1 REAR PANEL A. Per fig. 1, install 4 pieces of weather seal on the inside of the two middle uprights on the rear screen. B. With the bulb rubber facing forward, install the rear panel in front of the rear screen by pushing down over the seat back mounts. STEP 2 REAR MOUNT A. Per fig. 2, install the rear mount by placing it between the front and rear cab bars and reinstalling the bars removed in Vehicle Prep step B. NOTE: Do not tighten bolts. STEP 3 SIDE FRAME INSTALLATION A. Remove the protective film from the side frame windows before installing to the vehicle. B. Per fig. 3, install supplied pieces of Expand-a-foam to front cowl as shown. NOTE: Adhesive seal should be applied to a clean, dry surface at room temperature for best adhesion. Fig. A1 Fig. A2 Fig. B Fig. C Fig. 1 Fig. 2 Fig. 3 p. 3 of 7
STEP 3 SIDE FRAME INSTALLATION (continued) C. (Figure 6) With assistance, install the left and right side frames by inserting the upper rear corner behind the rear mount installed in Step 2. Pivot the front of the frame down onto the front fenders. Place side frame floorboards on to the vehicle floor. Attach side frames to rear mount with 5/16" x 3/4" carriage bolts (one per side). D. (Figure 7) Install the front mounts to the left and right side frames with 5/16" x 3/4" bolts, and washers, provided. STEP 4 FUEL FILLER INSTALLATION A. (Figure 8) Tip the front seat bottom forward, remove the cap from the fuel tank, and install the fuel filler to the right side frame with four 10-32 machine screws provided. Install fuel filler gasket by pressing over neck of fuel tank. Re-install fuel tank cap. STEP 5: WINDSHIELD & WINDSHIELD SUPPORT A. (Figure 9) Bolt the windshield support to the left and right side frames with 5/16 x 3/4 carriage bolts in the lower holes only (1 per side). Install with six slots at top of support. Align outer edges of windshield support with edges of side frames and tighten carriage bolts. B. (Figure 10). With assistance, lift the windshield onto the front of the side frames and bolt hinges to windshield support with hinge spacers, 5/16 X 1-3/4 flat head bolts, washers, and locknuts. Align sides of windshield with side frames and while holding in position close latches against the back side of the windshield strikers. NOTE: If the windshield does not seal to the side frames near the bottom, it is hitting the hood too hard, undo the latches and adjust the windshield up. If it does not seal against the hood, adjust the windshield down. Tighten bolts to 7 ft-lbs. CAUTION: Do not over torque fasteners through plastic hinges. C. (Figure 11 next page) Install the supplied gas springs to the windshield and side frames with the piston pointing down. Push gas spring ends over ball studs and snap covers into place to secure. Figure 6 Figure 7 Figure 8 Figure 10 Figure 9 p. 4 of 7
STEP 6: ROOF A. Use a Phillips head screwdriver to punch a hole through the headliner at all of the covered bolt hole locations (8 places). Punch holes from the inside out to avoid having the headliner pull away from its glued surface. B. (Figure 12) With assistance, install the roof. Use 5/16-18 x 1 long carriage bolts in the front corners, use 3/4" long carriage bolts in the remaining six holes. STEP 7 POSITION AND TIGHTEN CAB A. Check that the rear mount is centered left to right and tighten the bolts on the R.O.P.S. installed in step 2. B. (Figure 13) Check that the carriage bolt in the top rear of the left side frame is centered (left to right) on the slot in the rear mount and tighten the bolt. Repeat for right side. Figure 11 C. Tighten the front mount. D. Tighten all remaining cab hardware, aligning parts as you go. Install the supplied nut covers. E. (Figure 14) Align edge of side frame floorboard with edge of plastic trim on vehicle floor. Use bar clamp if necessary. Drill 3/8" holes through vehicle floor using the slotted holes in the side frame as a guide. Attach w/ 3/4" long carriage bolts with washers and locknuts under the vehicle. Figure 12 Figure 13 Figure 14 p. 5 of 7
STEP 8 REAR CAB FILLERS A. (Figure 15 and 16) Install left and right fillers by snapping into place and applying adhesive backed Velcro as necessary. NOTE: Adhesive backed Velcro should be applied to a clean, dry surface at room temperature. STEP 9 FINISHING TOUCHES A. Install hardware to rear screen and seat back removed in Vehicle prep. Tighten all hardware. Figure 15 B. (Figure 17) Install rubber seals to edges of hood as shown. CARE AND MAINTENANCE A. Check and tighten hardware after 40 hours of operations. Periodically inspect and tighten hardware for the remainder of the unit s life. B. Wash the painted surfaces of the unit with commercial automotive cleaning products. C. Clean windows with glass cleaner. D. Vinyl components should be washed with a mild solution of warm soapy water. Figure 16 (filler shown in yellow for clarity) Clear vinyl can be easily scratched. Be careful cleaning frost or snow from windows. Do not roll curtains in cold weather. The windows become stiff and may crack. Keep curtain clean. Figure 17 p. 6 of 7
KAWASAKI MULE 4000 CAB PARTS LIST p/n KAF40-005BA (BLACK) & KAF40-005WA (WHITE) * HEADLINER OFF WHITE OR WINDSHIELD SUPPORT * 1/2" WEATHER SEAL (INSIDE) (9PR20) ROOF * 1 KA4000-01 TRIM-LOK (3 SIDES) *REFLECTORS 1 KAM4T4-03 * HEYCO PLUGS * RELEASE LATCHES & SPACERS WINDSHIELD REAR PANEL *HINGES W/ NYLON SPACERS SEAM BULB 1 KAM4T4-02 * (2) HEYCO PLUGS * SEAM BULB GAS SPRING MOUNTS (BOTH POINT ) 3/4" SIDE BULB W/ 1/4" GRIP (9PR38) 1 KA3000-06 * 7/16" SIDE BULB 1/4" GRIP * SERIAL # DECAL, OPTIONS DECAL, AND W/S WARNING DECAL (INSIDE) *1/2" WEATHER SEAL (INSIDE) REAR MOUNT (9PR20) 1 KA4000-04 UNITIZED SIDE FRAMES 1 KAF4000-09L 1 KAF4000-09R UPPER MOUNTS RUBBER COATED 2 KAFT4-04 * BALL STUD * LATCH PIN * SNAPS 3 PER SIDE (INSIDE) * HINGE SLEEVES (HS-P1) * 3/8" HEYCO PLUGS. 2 THIS SIDE ONLY REAR FILLERS 1 KA4000-08L 1 KA4000-08R (RUBBER) * 5/8" OFFSET SIDE BULB FUEL FILLER 1 KAM4T4-13 * 1/2" WEATHER SEAL (INSIDE) 4 SIDES (9PR20) TRIM LOCK 1/4" x 3/4" EXPAND-A-FOAM 5/8" OFFSET SIDE BULB 1/2" WEATHER SEAL 3/4" SIDE BULB W/ 1/4" GRIP 7/16" SIDE BULB W/ 1/4" GRIP 9PRO1 9PR30 9PR27 9PR20 9PR38 ADDITIONAL SERVICE PARTS QTY/CAB p/n DESCRIPTION 1 9GL-34x56 MOLDED WINDSHIELD ASSEMBLY 2 9PH007 & 9BLK01 POP OUT WINDSHIELD HINGE KIT-SINGLE 1 9WL02L POP OUT WINDSHIELD RELEASE LATCH KIT-LH 1 9WL02R POP OUT WINDSHIELD RELEASE LATCH KIT-RH 2 9WL02E POP OUT WINDSHIELD LATCH EXTENSIONS 4 HS-P1 UNITIZED FRAME HINGE SLEEVES 1 KAT4-10 FUEL FILLER GASKET 1 KAT4HWK-01 HARDWARE FASTENER KIT 2 2 9GS09 PG-4000SF WINDSHIELD GAS SHOCKS FRONT SIDE WINDOWS 9PR29 p. 7 of 7