Assembly Instructions Part Number Description Model Approx. Assembly Time 99994-0903 Windshield Wiper Kit Mule SX 1 Hour WARNING Improper installation of this accessory could result in an accident causing serious bodily injury or death. To prevent an accident, be sure that this accessory is properly and securely installed on your vehicle. If you cannot properly install this accessory yourself, have a professional installer, such as an authorized Kawasaki dealer, install it for you. Prior to each use, check to be sure the accessory is securely attached to the vehicle and periodically inspect the accessory for any required adjustment, wear, and damage. NOTE: Prior to installing this kit, the installation of Cab Enclosure (99994-0849) is required. 2016 Kawasaki Motors Corp., U.S.A. Page 1 of 11
Parts List: Ref. # Description Qty A01 Wiper Motor (110 ) 1 A02 Wiper Arm, (Adjustable 11-16 ) 1 A03 Wiper Blade (20 ) 1 A04 Large Nylon Bushing 1 A05 1/4-20 x 5/8 Hex Screw 1 A06 1/4 Internal Tooth Lock Washer 1 A07 Small Nylon Bushing 1 A08 5/8 ID Rubber Washer 1 A09 5/8 ID Black Steel Washer 1 A10 1/4-20 Stainless Steel Cap Nut 1 A11 Short Wire Harness 1 A12 Long Wire Harness 1 A13 11 Black Wire Tie 3 A14 3/4 ID Rubber Grommet 2 A15 7/16 ID Rubber Grommet 1 Parts Diagram: A05 A06 A11 A07 A01 A12 A08 A09 A13 A04 A03 A14 A10 A15 A02 Page 2 of 11
NOTE: 1. If installing windshield wiper kit and cab enclosure at the same time proceed with installation instructions. 2. If cab enclosure has been previously installed proceed to Installation After Cab is Installed on page 8. Installation Instructions: 1. Park the vehicle on level ground, set the parking brake and turn off the ignition switch. 2. Lift seat forward to gain access to the battery. 3. Disconnect the negative battery terminal. 4. Drill the passengers side of dashboard with an 11/16 bit at location shown in diagram. Roughly 1-3/8 up from the fender and 1-13/16 in from the side of the hood. 5. Deburr both the inside and outside edges of the hole. Drill 11/16 Hole 1-13/16 + 1-3/8 6. Remove and save the (15) dart clips and (1) phillips head screw securing the hood panel and remove the hood. NOTE: If necessary, remove the grill assembly and the front bumper as described in the service manual. 7. Disconnect the ground wire (black wire with yellow stripe) from the back of the 12 volt outlet. Dart Clip Phillips head Screw 8. Disconnect the power wire (brown wire with red stripe) from the back of the 12 volt outlet. Page 3 of 11
9. Push on the piggyback terminal which is connected to the white wire of the supplied short wire harness (A11) to the copper tab with the (+) marking on the back of the 12V outlet. A11 10. Reconnect the power wire (brown wire with red stripe) to the piggyback terminal installed in the previous step. 11. Push on the piggyback terminal which is connected to the black wire of the supplied short wire harness (A11) to the tab with the (-) marking on the back of 12V outlet. A11 12. Reconnect the ground wire (black wire with yellow stripe) to the piggyback terminal installed in the previous step. 13. Route the loose end of the supplied short wire harness (A11) through the previously drilled hole on the passenger s side of the dashboard (step 4). A11 14. Secure short wire harness (A11) to vehicle chassis with 2 of the 3 wire ties (A13). NOTE: Orient the fuse holder to maintain future access from below the dashboard. A13 A11 Page 4 of 11
15. Position the hood back on vehicle. 16. Reinstall hood dart clips and phillips head screw. 17. Locate the right cab side frame and remove and discard the (2) plastic plugs and replace with the (2) supplied rubber grommets (A14). Right Side Frame NOTE: To avoid marring the paint when removing the plastic plugs, drive a screwdriver through the center of the plug and gently work out. 18. Thread long wire harness (A12) by feeding the bullet terminal end of harness through the upper most hole down and out through the lower hole in right side frame. NOTE: It may be helpful to use a wire or string as an aid to fish the harness down through the side frame tube. 19. Complete cab installation. 20. Connect the terminals coming through the hole drilled in dashboard to the ones hanging from the lower right side frame hole. A14 A12 Page 5 of 11
21. Feed the connection into the hole drilled into the dashboard. Make a slice in the supplied grommet (A15) wrap around wire and install into the hole in the dashboard. A14 A15 A12 22. Route the end of the long wire harness (A12) with the molded plug along the ROPS tube and down through the rubber grommet in the W/S support. A13 23. Use remaining wire tie (A13) to secure wire harness (A12) to ROPS cross-member. 24. Remove the plastic plugs from the windshield. A12 25. Assemble wiper motor to the inboard side of the windshield according to the diagram below. Align the wiper motor shaft with the larger of the two holes in windshield and wiper motor mounting ear with the smaller. A06 A05 A07 A01 A09 A08 A10 A04 A03 A02 Page 6 of 11
26. Connect wire harness (A12) to wiper motor (A01). 27. Reconnect negative battery terminal. 28. Turn motor on and off to cycle it back to the parked position. 29. Remove the screw and locknut from the wiper arm. 30. Insert the screw through the upper mounting hole in the wiper blade, then the wiper arm, and back through the wiper blade securing with the locknut. 31. Lift the locking tab on the underside of the wiper arm and extend the wiper arm to the desired length. The angle of the blade can be adjusted by loosening the small bolt on the top of the wiper arm. Locknut Angle Adjustment Bolt Length Adjustment Tab NOTE: Be sure the set screws found in the head of the wiper arm don t protrude into the knurled mating surface, loosen screws to avoid any interference when installing onto wiper motor shaft. 32. Press the wiper arm onto the shaft so that it is positioned at seven (7) o clock position. Turn the wiper motor on and test its operation. Adjust the arm sweep by turning the blade, adjusting the arm length, or removing the wiper arm off of the motor shaft and reinstalling it at a different position. 33. Make sure wiper arm is fully seated on wiper motor shaft. See adjacent photos for proper and improper wiper arm installation onto the splined shaft of the wiper motor. 34. Once wiper is fully adjusted, tighten the set screw on the wiper arm. The set screw location is noted in illustration at location A. NOTE: Properly installed. Notice finger is beyond the splined area. A02 A Page 7 of 11
NOTE: Improperly installed. Finger sitting on the splined area. NOTE: A mirror was used in both photos in order to clearly see and confirm the spring clip engagement. It is strongly suggested to double check the spring clip engagement using a mirror as illustrated. It may be necessary to lightly tap the arm with a rubber mallet to fully seat the arm. NOTICE To avoid breaking the windshield, support the wiper motor with your hand when tapping the arm. Wear safety glasses! Installation After Cab is Installed: NOTE: Unless otherwise specified, leave all cab enclosure hardware loose for later adjustment. 1. Park the vehicle on level ground, set the parking brake and turn off the ignition switch. 2. Lift seat forward to gain access to the battery and disconnect the negative terminal. 3. Remove and set aside the (2) 5/16-18 x 3/4 long button head, flanged cap screws & (2) 5/16-18 flange nyloc nuts retaining the windshield latch brackets to the right side frame. Page 8 of 11
4. Repeat step 3 for the left side. NOTE: Once the windshield hinge fasteners are removed during the next step the windshield assembly could fall! Proceed with caution. 5. With help from an assistant, remove and set aside the (4) 5/16-18 x 1-1/2 long flat head screws & (4) 5/16-18 flange nyloc nuts fastening the windshield assembly to the windshield support assembly. (Roof not shown for clarity). Windshield Assembly Windshield Support Assembly 6. With help from an assistant, remove the windshield assembly and place it aside. 7. Remove and set aside the (6) 5/16-18 x 3/4 long button head, flanged cap screws retaining the cowl assembly to the side frames. Cowl Assembly 8. Follow steps 4-18 of Installation Instructions starting on page 3 of this manual. 9. With help from an assistant place the cowl assembly in position over the vehicle s hood compressing the seal. Fasten cowl with (6) 5/16-18 x 3/4 long button head, flanged cap screws removed in step 7. 10. With help from an assistant, reinstall the windshield assembly and the (4) 5/16-18 x 1-1/2 long flat head screws & (4) 5/16-18 flange nyloc nuts removed during step 5. Page 9 of 11
11. Install the fasteners which were removed in step 3, (2) 5/16-18 x 3/4 long button head, flanged cap screws & (2) 5/16-18 flange nyloc nuts which retain the windshield latch brackets to the right side frame. 12. Repeat step 11 for the opposite side. 13. Close windshield latches and tighten windshield hinge fasteners then the windshield latch bracket bolts. NOTE: The windshield hinges are plastic components. Do not over tighten the 5/16-18 flat head screws. Torque to no more than: 9.5 N m (.97 kgf m, 7 ft lb). NOTE: The windshield hinges mount to the windshield support via slots. If need be, loosen hinge hardware & push windshield up or down in slots to attain better windshield to side frame seal. 14. Tighten all remaining 5/16-18 hardware, 25.5 N m (2.63 kgf m, 19 ft lb). 15. Complete the remainder of the installation by following steps 20-34 of Installation Instructions starting on page 5 of this manual. Page 10 of 11
Service Parts Breakdown 1 2 3 7 6 8 9 4 10 5 Page 11 of 11