p/n: IM-99994-0849

Assembly Instructions

Part Number Description Model Approx. Assembly Time

99994-0849 Cab Enclosure MULE SX 3-4 Hours

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 periodi-cally inspect the accessory for any required adjustment, wear, and damage.

Rev. 2, p. 1 of 16

9994-0908 Windshield Assist Shocks (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)

Options Available:

Parts List: Ref. # Description Qty A01 Rear Panel Assembly 1

A02 ROPS Bracket 2

A03 Left Side Frame Assembly 1

A04 Right Side Frame Assembly 1

A05 Windshield Support Assembly 1

A06 Cowl Assembly 1

A07 Windshield Assembly 1

A08 Roof Assembly 1

A09 Left Side Door Assembly 1

A10 Right Side Door Assembly 1

A11 Velcro “Hook” (169”) 1

A12 Adhesive Backed Foam (18”) 1

A13 Under-seat Filler 1

- Hardware Kit (Not Shown) 1

A14 Gas Shocks 2

Parts Diagram:

p. 2 of 16

A07

A10

A05 A08

A01

A04

A03

A13

A12

A02 A06

A02

A11

A09

A14

General Information:

Tools Required:

p. 3 of 16

 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 com-plete.

Set of Standard and Metric Sockets (3/8” Drive) 3/8” Drive Ratchet Set of Standard and Metric Open End Wrenches Set of Standard Allen Wrenches 9.5 Nm (7 ftlb) to 98 Nm (72 ftlb) Torque Wrenches

Drill 3/8" Drill Bit Pair of Scissors Grease Silicone Sealant Isopropyl Alcohol or Other Cleaner

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.

Note: Unless otherwise specified, leave all Cab Enclosure hardware loose for later adjustment.

Optional wiper wiring must be installed prior to beginning cab installation.

Installation Instructions: 1. Park the vehicle on level ground, set the parking

brake, turn off the ignition switch.

2. If installing wiper or other electronic accessories, remove hood and connect wiring at this 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.

7. Per fig. 7, assemble the Rear Panel Assembly (A01) to the ROPS. Reinstall the upper rear ROPS bolts.

Note: Do not tighten upper rear ROPS bolts at this time.

8. Clean the metal surface below the rear window to remove dirt, oil, or grease.

9. Per fig. 9, cut a 48-1/8” long piece of Velcro “hook” (A11). Adhere just above the (3) pre-installed snaps. Components must be at room temperature for proper adhesion.

10. Flip lower portion of seat up and fasten the (3) snaps on the Under-seat Filler(A13) to the (3) snaps installed on the Rear Panel. Fit the Under-seat Filler down the rear of the ROPS and along top of the chassis (beneath seat).

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A01

Fig. 7

A01

A11

Fig. 9

p. 5 of 16

Installation Instructions:

11. Ensure vehicle seatbelt brackets protrude through the Under-seat Filler holes then reinstall the seat-belts which were removed in step 4.

12. Torque seatbelt hardware to: 34 N･m (3 kgf･m, 25 ft･lb)

13. Reinstall the seat back.

14. Per fig. 14, remove and save (2) ROPS bolts. Pull ROPS tube away from vehicle slightly and slip Front ROPS Bracket (A02) between ROPS tube and its mounting surface. Align holes and reinstall bolts. Repeat for other side.

15. Front ROPS bolts may be torqued at this time. 98 N･m (10 kgf･m, 72 ft･lb)

16. Remove door (A09) from side frame assembly(A03)

17. Per fig. 17, cut approximately 2-1/2” long piece of the provided Adhesive Backed Foam (A12) 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.

A02

Fig. 14

A12

A03

Fig. 17

Installation Instructions:

18. 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. Per fig. 20, position the Left Side Frame Assembly (A03) on top of vehicle’s floor-board. Secure with (5) 5/16-18 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.

22. Per fig. 22, install the Windshield Support Assembly (A05). Use (4) 5/16-18 x 3/4” long button head, flanged cap screws.

23. Per fig. 23, prepare Cowl Assembly (A06) for installation by cutting (2) 5-1/2” long pieces of the provided Adhesive Backed Foam (A12) and adhering to the Cowl’s Bulb Rubber at locations in diagram. Po-sition them to seal into the sharp corners on the hood valleys.

p. 6 of 16

A03

Fig. 20

A05

Fig. 22

A06

A12

Fig. 23

Installation Instructions: 23. Per fig. 23, place the Cowl Assembly

(A06) in position over the vehicles hood compressing the previously install foam. Fasten Cowl with (6) 5/16-18 x 3/4” long button head, flanged cap screws.

24. Per fig. 24, install Windshield Assembly (A07) to Windshield Support (A05) using a plastic spacer block beneath each plas-tic hinge spacing it off the Windshield Support. Snug fasteners, but do not fully tighten. Use (4) 5/16-18 x 1-1/2” long flat head screws & (4) 5/16-18 flange nyloc nuts.

25. Per fig. 25, fasten the Windshield Latch Brackets (which are pinned to the wind-shield latches) to the corresponding tabs welded to each of the Side Frames. Snug fasteners, but do not fully tighten. Use (4) 5/16-18 x 3/4” long button head, flanged cap screws & (4) 5/16-18 flange nyloc nuts.

p. 7 of 16

Fig. 23

A06

Fig. 24

A05 A07

Fig. 25

Installation Instructions: 26. See fig. 26, with help from an assistant,

place the Roof Assembly (A08) on top of the Side Frames. Align the (2) holes la-beled (X) with Side Frame inserts on ei-ther side first. Secure with (10) 5/16-18 x 3/4” long button head, flange screws, (10) 5/16” nylon flat washers and (3) 5/16-18 nylon nuts.

27. Tighten all Cab Enclosure bolts. Use caution when tightening roof bolts to avoid crushing the nylon washers.

28. Close windshield latches and tighten Windshield hinge fasteners then the wind-shield latch bracket bolts.

Note: The windshield hinges are plastic com-ponents. 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).

29. Rear ROPS bolts may be torqued at this time. 44 N･m (4 kgf･m, 32 ft･lb)

30. Using the Side Frame’s (A03) floorboard holes as a guide, drill the vehicle’s floor-board with a 3/8” drill bit.

31. Per fig. 31, secure the Side Frame’s (A03) floorboard with (2) 5/16-18 x 3/4” long button head, flanged cap screws, (2) 5/16” x 1” steel fender washers and (2) 5/16-18 nyloc nuts.

32. Repeat steps 30 & 31 on the right side.

p. 8 of 16

A08

X

X

Fig. 26

A03

Fig. 31

Installation Instructions: 33. Clean surfaces of the Left Side Frame (A03)

depicted in the adjacent diagram to remove dirt and any oil or grease.

34. Per fig. 34, cut (2) pieces of Velcro “Hook” (A11) and adhere to the Left Side Frame (A03).

35. Clean surfaces of the Right Side Frame (A04) depicted in the adjacent diagram to remove dirt and any oil or grease.

36. Per fig. 36, cut (2) pieces of Velcro “Hook” (A11) and adhere to the Right Side Frame (A04).

p. 9 of 16

Fig. 34

Velcro Hook, 17-1/8” Long

Velcro Hook, 4-7/8” Long

Velcro Hook, 17-1/8” Long

Velcro Hook, 7-5/8” Long

Fig. 36

Installation Instructions: 37. Tilt the lower portion of the seat up.

38. See fig. 38, using the Velcro “Loop” that’s sewn to the Under-seat Filler as a guide, adhere the remaining Velcro “Hook” (A11) to the vehicles chassis beneath the seat.

Note: Take care routing Velcro and Under-seat Filler around Emergency Brake handle. This area should be clear of obstructions.

39. Fit Lower Rear Curtain down along Side Frames, around the vehicle’s ROPS and then under the seat pressing into the Velcro.

40. Pass zip ties through the two sets of 1/4” holes found in the Lower Rear Curtain wrapping around chassis at locations “B”. (See fig. 38)

p. 10 of 16

A11

B

B

Fig. 38

Installation Instructions: 41. Grease door hinge pins and reinstall

doors.

42. Per fig. 42, install the door gas shocks (A13) with the quick release end attached to the side frame ball stud.

43. 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 us-ing (2) 3/4” open end wrenches, per fig. 43.

p. 11 of 16

A13

A09

Fig 43

Fig. 42

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 wind-shield 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 op-erating 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.

Operation p. 12 of 16

Service Parts Breakdown ITEM #: PART NUMBER: QTY/KIT: DESCRIPTION:

1 xxx 1 ROOF, ASSEMBLY, KSX2 xxx 1 WINDSHIELD ASSEMBLY. KSX3 xxx 1 WINDSHIELD SUPPORT ASSEMBLY. KSX4 xxx 1 COWL ASSEMBLY, KSX5 xxx 1 ROPS BRACKET, KSX6 xxx 1 ROOF, HEADLINER7 xxx 1 TRIM LOK, STD, 1/8" GRIP (181)"8 xxx 1 DOME PLUG, 7/16"9 xxx 1 DOME PLUG, 3/8"10 xxx 1 3/4" SIDE BULB RUBBER (169.75")11 xxx 1 HINGE ASSEMBLY12 xxx 1 LATCH, POP-OUT, SINGLE ARM13 xxx 1 WINDSHIELD LATCH BRACKET, LEFT, KSX14 xxx 1 WINDSHIELD LATCH BRACKET, RIGHT, KSX15 xxx 1 POLY INSERT, 3/4"16 xxx 1 POLY INSERT, 1"17 xxx 1 POLY INSERT, 7/8"18 xxx 1 RUBBER GROMMET

19 xxx 1 1/2" V-GROOVE WEATHERSEAL (8")

20 xxx 1 CURTIC CONTACT DECAL

21 xxx 1 OPTIONS DECAL

22 xxx 1 MFG CODE LABEL

23 xxx 1 1/2" V-GROOVE WEATHERSEAL (6.25")

24 xxx 1 5/8" STANDARD BULB (51.125")

KAWASAKI MULE SX CAB ENCLOSURE

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19

19

22

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9 21

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23 23

24

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Service Parts Breakdown ITEM #: PART NUMBER: QTY/KIT: DESCRIPTION:

1 xxx 1 DOOR ASSEMBLY, LEFT, KSX2 xxx 1 DOOR ASSEMBLY, RIGHT, KSX3 xxx 1 HINGE SLEEVE, OFFSET STYLE4 xxx 1 SLIDING WINDOW, LEFT5 xxx 1 SLIDING WINDOW, RIGHT6 xxx 1 WINDOW MOUNTING RUBBER (87.5")7 xxx 1 3/4" SIDE BULB RUBBER (160.75)8 xxx 1 DOOR LATCH BAR, RIGHT9 xxx 1 DOOR LATCH BAR, LEFT10 xxx 1 DOOR HANDLE, OUTSIDE, PLASTIC11 xxx 1 BALL STUD, 5/16-1812 xxx 1 LATCH, POP-OUT, SINGLE ARM GAS SHOCK13 xxx 1 WINDSHIELD LATCH BRACKET, LEFT, KSX

KAWASAKI MULE SX CAB ENCLOSURE

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12

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3

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9

13

1

3

3

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8

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7

4

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Service Parts Breakdown ITEM #: PART NUMBER: QTY/KIT: DESCRIPTION:

1 xxx 1 SIDE FRAME ASSEMBLY, LEFT, KSX2 xxx 1 SIDE FRAME ASSEMBLY, RIGHT, KSX3 xxx 1 SIDE FRAME WINDOW ASSEMBLY, LEFT, KSX4 xxx 1 SIDE FRAME WINDOW ASSEMBLY, RIGHT, KSX5 xxx 2 HINGE PIN, OFFSET STYLE, LEFT6 xxx 2 HINGE PIN, OFFSET STYLE, RIGHT7 xxx 5 STRIKER BOLT8 xxx 1 BALL STUD9 xxx 1 DOME PLUG, 1"10 xxx 1 GROMMET BUMPER11 xxx 1 DOME PLUG, 5/16"12 xxx 1 MULE SX DECAL13 xxx 1 POLY INSERT, 3/4" X 2"14 xxx 1 5/8" BULB RUBBER (41.75")15 xxx 1 5/8" BULB RUBBER (21.5")16 xxx 1 5/8" BULB RUBBER (4.25")17 xxx 1 TRIM-LOK, STD (20.5")18 xxx 1 TRIM-LOK, STD (9.375")

19 xxx 1 TRIM-LOK, STD (5.625")

KAWASAKI MULE SX CAB ENCLOSURE

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18

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16

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11

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4

9

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Service Parts Breakdown ITEM #: PART NUMBER: QTY/KIT: DESCRIPTION:

1 xxx 1 REAR PANEL ASSEMBLY, KSX2 xxx 1 REAR FILLER PANEL3 xxx 1 REAR PANEL WINDOW4 xxx 1 WINDOW MOUNTING RUBBER (115.125")5 xxx 1 1/2" V-GROOVE WEATHERSEAL6 xxx 1 HARDWARE KIT

KAWASAKI MULE SX CAB ENCLOSURE

2

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3 4

HARDWARE KIT 4X— SCREW, FLAT HEAD, 5/16”-18 X 1-1/2”LG (P/N xxx) 15X— NUT , HEX FLANGE, NYLON INSERT, 5/16”-18 (P/N xxx) 8X— STEEL WASHER, 5/16” ID X 1” OD. (P/N xxx) 38X— SCREW, BUTTON FLANGE, 5/16”-18 X 3/4” LG (P/N xxx) 10X— NYLON WASHER, 5/16” ID X .69” OD (P/N xxx)

6 1 3 4

5