Assembly Instructions Part Number Description Model Approx. Assembly Time 99994-049 Cab Enclosure MULE SX 3-4 Hours 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. Options Available: 99994-090 Windshield Gas Shock (not shown) 99994-0905 Side View Mirrors (shown) 99994-0906 Interior Rear View Mirror (not shown) 99994-0903 Windshield Wiper (shown) KAF600-025A Snow Plow (not shown) KAF600-015A Heater (not shown) 2016 Kawasaki Motors Corp., U.S.A. Page 1 of 1
Parts List: Ref. # Description Qty A01 Windshield Assembly 1 A02 Right Side Door Assembly 1 A03 Windshield Support Assembly 1 A04 Roof Assembly 1 A05 Rear Panel Assembly 1 A06 Under-seat Filler 1 A07 Cowl Assembly 1 A0 ROPS Bracket 2 A09 Adhesive Backed Foam (1 ) 1 A10 Right Side Frame Assembly 1 A11 Left Side Frame Assembly 1 A12 Left Side Door Assembly 1 A13 Velcro Hook (169 ) 1 A14 Gas Shocks 2 A15 Zip Tie 2 - Hardware Kit (Not Shown) 1 Parts Diagram: A03 A04 A05 A02 A01 A10 A11 A06 A07 A0 A09 A09 A0 A12 A14 A13 A15 Page 2 of 1
WARNING S e r i o u s I n j u r y o r D e a t h This cab enclosure does not provide protection from rollover or other accidents. This cab enclosure does not provide protection from flying objects including golf balls. This cab enclosure does not provide protection from lightning. When lightning threatens take cover and do not operate vehicle. WARNING 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. General Information: A. Refer to parts diagram on page 2 of this manual to help identify parts during the assembly process. B. Read and understand all instructions before beginning. C. Apply a silicone sealant to seal any minor gaps which may occur due to vehicle variations. D. Use caution to avoid damaging the factory installed threaded inserts. Begin the bolt engagement by hand to guard against potential cross threading. E. Installation of bulky and heavy cab parts are best done with an assistant. Tools Required: Set of Standard and Metric Sockets (3/ Drive) 3/ Drive Ratchet Set of Standard and Metric Open End Wrenches Set of Standard Allen Wrenches 9.5 Nm (7 ft lb) to 9 Nm (72 ft lb) Torque Wrenches Right Angle Screwdriver #3 Screwdriver Drill 3/" Drill Bit Pair of Scissors Grease Silicone Sealant Isopropyl Alcohol or Other Cleaner Page 3 of 1
NOTE: 1. Unless otherwise specified, leave all cab enclosure hardware loose for later adjustment. 2. It s recommended electrical accessories be wired into the dashboard connections prior to cab installation. If done at a later time, wiring cannot be completed without partial disassembly of the hard cab. Installation Instructions: 1. Park the vehicle on level ground, set the parking brake and turn off the ignition switch. 2. If installing wiper or other electronic accessories, remove hood and connect wiring at this time. Partial disassembly of the cab will be required for electrical connections at a later time. 3. Remove and save the (2) seat back retaining nuts and seat back itself then place aside. 4. Remove and save left, right and center seatbelts. 5. Loosen front ROPS (Roll-Over Protective Structure) bolts on both sides of vehicle. 6. Remove and save upper rear ROPS nuts, bolts & flat washers. 7. Assemble the rear panel assembly (A05) to the ROPS. Reinstall the upper rear ROPS bolts and nuts with flat washers on the inboard side only. A05 NOTE: Do not tighten upper rear ROPS bolts at this time.. Clean the metal surface below the rear window to remove any dirt, oil or grease. 9. Cut a 4-1/ long piece of velcro hook (A13). Adhere just above the (3) pre-installed snaps. Components must be at room temperature for proper adhesion. A05 A13 Page 4 of 1
10. Flip lower portion of seat up, pull the left side of the under-seat filler panel (A06) over the parking brake lever and left seat belt bracket, then feed the center seat belts through the two holes in center of the panel and reinstall them, fasten the (3) snaps on the under-seat filler (A06) to the (3) snaps installed on the rear panel (A05). Fit the under-seat filler down the rear of the ROPS and along top of the chassis (beneath seat). 11. Ensure vehicle seatbelt brackets protrude through the under-seat filler holes then reinstall the seatbelts which were removed in step 4. Snaps A05 12. Torque seatbelt hardware to: 34 N m (3 kgf m, 25 ft lb) A06 13. Reinstall the seat back. 14. Remove and save the (2) left ROPS bolts. Pull ROPS tube away from vehicle slightly and slip front ROPS bracket (A0) between ROPS tube and its mounting surface. Align holes and reinstall bolts. Repeat for other side. A0 15. Torque front ROPS bolts at this time. 9 N m (10 kgf m, 72 ft lb) 16. Remove the left side door assembly (A12) from left side frame assembly (A11). 17. Cut approximately 2-1/2 long piece of the provided adhesive backed foam (A09) and adhere to the side frame s bulb rubber at the location in the diagram. This will seal the sharp corner between the side fender and hood. 1-1/2 A11 A09 Page 5 of 1
1. If installing the optional windshield assist shocks, assemble the brackets to the side frame at this time. 19. If installing the optional side view mirrors, assemble to the side frame at this time. 20. Position the left side frame assembly (A11) on top of vehicle s floorboard. Secure with (5) 5/16-1 x 3/4 long button head, flanged cap screws & (2) 5/16 x 1 steel fender washers. Do not tighten at this time. 21. Repeat steps 16-20 for the right side frame assembly. NOTE: Check to make sure the passenger side seatbelt retractor does not contact the side frame. If needed, adjust the angle of the retractor to maintain adequate clearance. See step 36 found on page 9 for further detail. A11 22. Install the windshield support assembly (A03). Use (4) 5/16-1 x 3/4 long button head, flanged cap screws. A03 23. Prepare cowl assembly (A07) for installation by cutting (2) 5-1/2 long pieces of the provided adhesive backed foam (A09) and adhering to the cowl s bulb rubber at locations in diagram. Position them to seal into the sharp corners on the hood valleys. A07 A09 Page 6 of 1
24. With help from an assistant place the cowl assembly (A07) in position over the vehicles hood compressing the previously install foam. Fasten cowl with (6) 5/16-1 x 3/4 long button head, flanged cap screws. A07 25. Install windshield assembly (A01) to windshield support assembly (A03) using a plastic spacer block beneath each plastic hinge spacing it off the windshield support. Snug fasteners, but do not fully tighten. Use (4) 5/16-1 x 1-1/2 long flat head screws & (4) 5/16-1 flange nyloc nuts. A01 A03 26. Fasten the windshield latch brackets (which are pinned to the windshield latches) to the corresponding tabs welded to each of the side frames. Snug fasteners, but do not fully tighten. Use (4) 5/16-1 x 3/4 long button head, flanged cap screws & (4) 5/16-1 flange nyloc nuts. Page 7 of 1
27. With help from an assistant, place the roof assembly (A04) on top of the side frames. Align the (2) holes labeled (X) with side frame inserts on either side first. Secure with (10) 5/16-1 x 3/4 long button head, flange screws, (10) 5/16 nylon flat washers and (3) 5/16-1 nylon nuts. X X A04 2. Tighten all cab enclosure bolts. 5/16-1 hardware, 25.5 N m (2.63 kgf m, 19 ft lb). NOTE: Use caution when tightening roof bolts to avoid crushing the nylon washers. 29. 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 5/16-1 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. 30. Rear ROPS bolts may be torqued at this time. 44 N m (4 kgf m, 32 ft lb) 31. Using the left side frame assembly (A11) floorboard holes as a guide, drill the vehicle s floorboard with a 3/ drill bit. 32. Secure the left side frame assembly (A11) floorboard with (2) 5/16-1 x 3/4 long button head, flanged cap screws, (2) 5/16 x 1 steel fender washers and (2) 5/16-1 nyloc nuts. 33. Repeat steps 31 & 32 on the right side. A11 Page of 1
34. Clean surfaces of the left side frame assembly (A11) depicted in the adjacent diagram to remove any dirt, oil or grease. 35. Cut (2) pieces of velcro hook (A13) and adhere to the left side frame assembly (A11). Velcro Hook, 17-1/ Long A11 Velcro Hook, 4-7/ Long 36. Clean surfaces of the right side frame assembly (A10) depicted in the adjacent diagram to remove any dirt, oil or grease. If the seatbelt retractor needs adjustment, remove the plastic plug from the right side frame assembly (A10) by pushing from the inside out to avoid damaging painted surfaces. A socket can then be inserted through the hole for easy access to the seatbelt bolt. 37. Cut (2) pieces of velcro hook (A13) and adhere to the right side frame assembly (A10). Velcro Hook, 17-1/ Long Velcro Hook, 7-5/ Long A10 Plastic Plug Page 9 of 1
3. Tilt the lower portion of the seat up. 39. Using the velcro loop that s sewn to the under-seat filler as a guide, adhere the remaining velcro hook (A13) to the vehicles chassis beneath the seat. A13 NOTE: Take care routing velcro and underseat filler around emergency brake handle. This area should be clear of obstructions. B 40. Fit under-seat filler down along side frames, around the vehicle s ROPS and then under the seat pressing into the velcro. 41. Pass zip ties (A15) through the two sets of 1/4 holes found in the under-seat filler wrapping around chassis at locations B. B Page 10 of 1
42. Grease door hinge pins and reinstall doors. 43. Install the door gas shocks (A14) with the quick release end attached to the side frame ball stud. A14 A09 A13 44. The door latches should double click for full engagement, proper closure and seal. If necessary, make adjustments to the striker pin position on the side frame using (2) 3/4 open end wrenches. Page 11 of 1
Operation Windshield Operation: OPENING: Position one hand on each handle so that you can operate both handles simultaneously. Lift both handles to unlock them and then push the handles to open the windshield to the venting position. Be sure to push the handles until they lock into the venting position. CLOSING: Position one hand on each handle so that you can operate both handles simultaneously. Lift both handles to unlock them and then slowly allow the windshield to close by supporting its weight while it is closing. After the windshield is in the closed position, push both handles down into the closed locked position. NOTE: Both handles should be locked in the venting position, or they should be locked in the closed position while operating the vehicle. There are no intermediate positions. Care and Maintenance: Check and tighten all hardware after 20 hours of operation. Periodically inspect and tighten hardware for the remainder of the unit s service life. Keep the enclosure components clean in order to prevent dust and dirt from forming an unattractive film. The life of your cab components depend upon following these care procedures: 1. NEVER USE AN ABRASIVE DETERGENT / VEHICLE CLEANER OR A WIRE BRISTLED BRUSH. Do not use any CITRUS BASED CLEANERS such as orange or lemon. 2. NEVER USE AN ALCOHOL-BASED PRODUCT FOR CLEANING PLASTIC WINDOWS. Do not use WINDEX, GLASS PLUS, FANTASTIC, etc. Use of these products will result in deterioration of the plastic windows. 3. Clean the enclosure surfaces thoroughly with warm soapy water and a COTTON cloth or chamois. Be sure to use mild soap, specifically a dish liquid or equivalent. Clean in a light circular motion for best results. 4. Remove grease and oil with mineral spirits and a COTTON cloth or chamois. Wiring After Cab Installation: 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) 5/16-1 x 3/4 long button head, flanged cap screws & (2) 5/16-1 flange nyloc nuts retaining the windshield latch brackets to the right side frame. Page 12 of 1
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) 5/16-1 x 1-1/2 long flat head screws & (4) 5/16-1 flange nyloc nuts fastening the windshield assembly (A01) to the windshield support assembly (A03). (Roof not shown for clarity). A01 A03 6. With help from an assistant, remove the windshield assembly and place it aside. 7. Remove and set aside the (6) 5/16-1 x 3/4 long button head, flanged cap screws retaining the cowl assembly (A07) to the side frames. A07. Follow the electrical accessory installation instructions. 9. With help from an assistant place the cowl assembly (A07) in position over the vehicle s hood compressing the seal. Fasten cowl with (6) 5/16-1 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) 5/16-1 x 1-1/2 long flat head screws & (4) 5/16-1 flange nyloc nuts removed during step 5. Page 13 of 1
11. Install the fasteners which were removed in step 3, (2) 5/16-1 x 3/4 long button head, flanged cap screws & (2) 5/16-1 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 5/16-1 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 5/16-1 hardware, 25.5 N m (2.63 kgf m, 19 ft lb). Page 14 of 1
Service Parts Breakdown Page 1 of 4 1 2 10 7 10 11 7 6 7 9 11 3 4 5 12 13 12 12 12 Page 15 of 1
Service Parts Breakdown Page 2 of 4 11 11 2 1 3 10 10 3 7 7 9 12 12 9 6 6 5 4 3 3 Page 16 of 1
Service Parts Breakdown Page 3 of 4 1 14 4 5 14 2 9 5 7 16 6 7 6 10 12 12 10 9 15 11 5 13 3 11 5 13 12 Page 17 of 1
Service Parts Breakdown Page 4 of 4 1 3 4 5 HARDWARE KIT 6 5 5 4X SCREW, FLAT HEAD, 5/16-1 X 1-1/2 LG 15X NUT, HEX FLANGE, NYLON INSERT, 5/16-1 2 X STEEL WASHER, 5/16 ID X 1 OD. 3X SCREW, BUTTON FLANGE, 5/16-1 X 3/4 LG 10X NYLON WASHER, 5/16 ID X.69 OD Page 1 of 1