Kawasaki MULE 600 SERIES - User Manual

INSTALLATION & OWNER’S MANUAL
Rev. G
p. 1 of 9
CAB INSTALLATION INSTRUCTIONS
KAWASAKI MULE 600 SERIES
HARD AND/OR SOFT SIDED CAB KIT (p/n KAF600-012)
(Note: hard sided doors, soft sided doors, and anti-draft panel are
sold separately but are included in these instructions.)
The contents of this envelope are the property of the owner.
Be sure to leave with the owner when installation is complete.
This cab is shown with the following optional equipment: hard sided doors, work lights,
windshield wiper, strobe light, and antenna for overhead console. Other options not
shown are: soft sided doors and an anti-draft panel for underneath the bench seat.
RECOMMENDATIONS:
1) It is recommended that the tire pressure be adjusted as follows when installing a cab
on this vehicle: front tires to have 11.5 p.s.i. and rear tires to have 18.0 p.s.i.
2) It is recommended that two (2) heavy-duty springs (p/n 92145-0400) be used in the
rear
suspension when installing a cab on this vehicle. It is also recommended to set
the spring adjusting sleeve of the rear
shock unit at the circled position in the chart
below (position 4).

Summary

Cab Installation Recommendations

Tire Pressure Adjustment

Adjust front tires to 11.5 p.s.i. and rear tires to 18.0 p.s.i. for cab installation.

Rear Suspension Spring Setup

Use heavy-duty springs and set rear shock adjusting sleeve to position 4 for cab installation.

Install Anti-Draft Panel

Install Front Mounts

Install Hard Rear Window or Soft Rear Curtain

Install Rear Roof Mount

Install Left Side Frame

Install Windshield Support

Install Windshield

Install Rubber Filler

Install Roof

Tighten All Bolts

Secure Floorboards

Install Gas Shocks

Install Hard Sided Doors or Soft Sided Doors

Finishing Touches

Care and Maintenance

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Kawasaki Mule 600 Series Hard and/or Soft Sided Cab Kit (p/n KAF600-012) is an accessory designed to enhance the utility and comfort of the Kawasaki Mule 600 series vehicle. This cab kit provides weather protection and can be configured with either hard-sided or soft-sided doors, along with an anti-draft panel, all of which are sold separately but are covered in these installation instructions. The kit is designed to integrate seamlessly with the vehicle, offering a more enclosed and protected environment for the operator and passenger.

Function Description

The primary function of the cab kit is to provide an enclosed space for the Kawasaki Mule 600 series, protecting occupants from various weather conditions such as rain, wind, and cold. It transforms an open utility vehicle into a more versatile, all-weather machine suitable for a wider range of tasks and environments. The cab's design aims to accommodate vehicle variations and ensure proper weather protection through careful adjustment and alignment of its components.

The cab system includes several key components:

• Roof: Provides overhead protection from sun and precipitation.
• Windshield: Offers frontal protection and visibility.
• Windshield Support: Structural component for mounting the windshield.
• Rear Roof Mount: Secures the rear of the roof and integrates with the rear window or curtain.
• Front Mounts: Connect the cab structure to the front of the vehicle.
• Unitized Side Frames: Form the side structure of the cab, supporting doors and other components.
• Anti-Draft Panel: Designed to reduce drafts, particularly underneath the bench seat, enhancing occupant comfort.
• Hard Sided Doors (Optional): Provide rigid side enclosure and improved security.
• Soft Sided Doors (Optional): Offer flexible side enclosure, often lighter and easier to remove.
• Hard Rear Window (Optional): Provides rigid rear enclosure and visibility.
• Soft Rear Curtain (Optional): Offers flexible rear enclosure.

The installation process involves securing these components to the vehicle's existing frame, with specific attention to alignment and sealing to ensure effective weatherproofing. The design incorporates features like expand-a-foam strips and plastic washers to create seals around fasteners and joints, minimizing gaps and drafts.

Important Technical Specifications

While specific dimensions and material compositions are not fully detailed, the manual provides critical technical recommendations and specifications related to installation and performance:

• Tire Pressure Adjustment:

  • Front tires: 11.5 p.s.i.
  • Rear tires: 18.0 p.s.i.
  • This adjustment is crucial to compensate for the added weight of the cab and maintain optimal vehicle handling and stability.

• Rear Suspension Springs:

  • Recommendation: Two (2) heavy-duty springs (p/n 92145-0400) for the rear suspension.
  • Spring Adjusting Sleeve Position: Set at position 4 (circled in the provided chart), indicating a stiffer setting suitable for heavier loads and rough terrain. The chart details spring force settings from 1 (Soft, Light Load, Smooth Terrain, Low Speed) to 5 (Stronger, Hard, Heavy Load, Rough Terrain, High Speed). Position 4 is a balanced setting for heavy loads and rough terrain.

• Fasteners and Torque:

  • Various carriage bolts (3/4" and 1" long) are used throughout the installation.
  • Flat head screws (1 3/4" long) with flat steel washers and locknuts are used for the windshield.
  • Windshield hinge torque: Maximum 7 ft. lbs. This is critical as the hinges are plastic components and overtightening can cause damage.
  • Plastic washers are supplied for exterior fasteners to create a weather seal, emphasizing the need for careful tightening to avoid damage.

• Material Components:

  • Rubber Types: The parts list includes various rubber seals: 5/8" Regular Bulb (9PR02), 3" Bulb Flat (9PR06), 3/4" Side Bulb W/ 1/4" Grip (9PR29), 1/2" Weather Seal (9PR20), 1/4" x 3/4" Expand-A-Foam (9PR30), 3/4" Offset Side Bulb W/1/4" Grip (9PR01), and Trim-Lok (9PR26). These are essential for sealing and weatherproofing.
  • Windshield: Made with plastic hinges and requires spacer blocks for mounting.
  • Anti-Draft Panel: Features a clear plastic window for visibility of the fuel gauge and uses adhesive-backed hook and loop (velcro) for attachment.
  • Headliner: Requires punching holes from the inside out to prevent pulling away from its glued surface.

• Weight Notice: The manual explicitly states that Curtis Cabs, blades, and general accessories add additional weight to the base vehicle. Users must deduct the accessory's total weight from the vehicle's rated capacity and never exceed the vehicle's rated capacity, including the driver and passenger.

Usage Features

The cab kit enhances the usability of the Kawasaki Mule 600 series in several ways:

• All-Weather Operation: Provides protection from elements, allowing the vehicle to be used comfortably in rain, wind, and cold.
• Improved Comfort: Reduces drafts and exposure, making long hours of operation more comfortable for occupants. The anti-draft panel specifically targets drafts from underneath the seat.
• Enhanced Visibility: The windshield and optional rear window maintain visibility while offering protection. The anti-draft panel's clear plastic window ensures the fuel gauge remains visible.
• Optional Accessories Integration: The design accommodates optional features like work lights, windshield wipers, strobe lights, and overhead console antennas, further customizing the vehicle's functionality.
• Adjustability: The installation instructions emphasize leaving bolts loose during initial assembly to allow for adjustment and alignment, compensating for vehicle variations and ensuring a proper fit and seal.
• Safety Features: Includes gas shocks for the windshield, allowing it to be opened and held in place. The doors, when installed, must be properly latched for safe operation, with a caution against driving with doors open.

Maintenance Features

The manual outlines several maintenance recommendations to ensure the longevity and proper functioning of the cab kit:

• Hardware Inspection and Tightening:

  • Initial check and tightening after 40 hours of operation.
  • Periodic inspection and tightening of hardware for the remainder of the unit's life. This is crucial for maintaining structural integrity and preventing components from loosening due to vibration and use.

• Cleaning:

  • Painted Surfaces: Wash with commercial automotive cleaning products.
  • Windows: Clean with glass cleaner.
  • Vinyl Components: Wash with a mild solution of warm soapy water.
  • Clear Vinyl Care: Emphasizes that clear vinyl can be easily scratched. Users are advised to be careful when cleaning frost or snow from windows and to avoid rolling curtains in cold weather, as they can become stiff and crack. Keeping windows clean is also recommended.

• Lubrication:

  • Apply lubricant (preferably grease) to the pin hinges of the doors during installation. This ensures smooth operation and prevents wear.

• Sealant Application:

  • Apply a clear silicone sealant to seal any minor gaps that may occur due to vehicle variations. This proactive measure helps maintain the weather seal over time.

• Component Replacement: The "Additional Service Parts" section in the parts list indicates that individual components like the windshield assembly, hinge kits, latch kits, frame hinge kits, hardware fastener kit, gas shocks, and window panels can be ordered separately, facilitating repairs and maintenance.

Overall, the Kawasaki Mule 600 Series Cab Kit is a comprehensive accessory designed to improve the functionality and comfort of the vehicle through careful engineering, detailed installation instructions, and clear maintenance guidelines. Its modular design, with optional doors and rear enclosures, allows for customization based on user needs and environmental conditions.

Kawasaki MULE 600 SERIES Specifications