ATV winches, mounts and accessories for KFI Products - KFI ATV Winch, Mounts and Accessories
Instruction Manual for Kawasaki models including: 101230 Kawasaki Mule Pro FXT, 101230, Kawasaki Mule Pro FXT, Mule Pro FXT, Pro FXT, FXT
Copyright ©2014 - Kappers Fabricating, Inc. Page 3 of 6 B - 12/1/2014 INSTALL SWITCH 15. Use included Mini-Rocker Switch Hardware Kit (HK-031) to fasten a handle bar ...
File Info : application/pdf, 6 Pages, 2.75MB
DocumentDocumentKawasaki Mule Pro FXT Winch Mount Part #: 101230 Hardware Kit: HK-129, HK-031 Contents: 1x 101231 - Winch Mount 1x 101236 - Support Channel Hardware Kit: 4x 3/8"-16 x 1-1/4" Hex Flange Bolt 2x 3/8"-16 x 1" Hex Flange Bolt 6x 3/8"-16 Hex Flanged Nylock Nut 1x 22-18GA Male Insulated Terminal 1x HK-031 (UTV Mini-Rocker Hardware) IMPORTANT: Installation of this winch mount requires KFI Part# UTV-WEK. INSTALLATION INSTRUCTIONS: Figure - A General assembly diagram. PREPARE MACHINE 1. Begin by turning the vehicle off. Locate and remove the battery compartment cover on the passenger side, behind the rear bench (Figure 1). Support Channel Use short bolts on bottom holes. Cover Figure - 1 Latch Figure - B Winch assembly view. 2. Remove both the front & rear skid plates under the INSTALL WINCH MOUNT TO FRAME vehicle, and the front hood panel. Figure 12 shows both skid plates removed. 4. Position the winch mount plate against the frame according to Figure A & Figure 3. First, loosely install **Note, you you have a 2018 or newer model, you two 3/8" x 1-1/4" Bolts with 3/8" Nylock Nuts at do not need to remove the skid plates. location (C1), then two 3/8" x 1" Bolts with Nuts at 3. Remove the front bumper by unfastening bolts shown location (C2). Do not fully tighten hardware at this in Figure 2 at locations (A) on both sides of frame, time. and three bolts at location (B). D A B Figure - 2 Copyright ©2014 - Kappers Fabricating, Inc. Figure - 3 Page 1 of 6 C1 Use shorter 3/8" x 1" C2 Bolts at (C2) B - 12/1/2014 5. Position the Support Channel behind and below the front radiator guard according to Figure A and Figure 4, sandwiching the winch mount plate and machine frame at bolt locations (D) in Figure 3. SUPPORT CHANNEL Guard Figure - 4 Viewed from passenger side, front end. Fig 5 - INSET Winch Wires Note: Mount Contator Block 1st. Contactor Block E E Battery: UTV-WEK (Fuse Panel) Pass two 3/8" x 1-1/4" Bolts through holes (D) in the winch mount plate, the machine frame, and Support Channel according to assembly Figure A. Loosely affix two 3/8" Nylock Nuts. 6. Fully tighten all winch mount hardware evenly. INSTALL WINCH TO WINCH MOUNT 7. Assemble your winch, fairlead bracket, and roller fairlead or hawse fairlead to the winch mount as shown in Figure B using hardware included with your winch. Note: If your winch did not come with a roller fairlead or fairlead bracket, you can purchase either separately. See www.kfiproducts.com or contact your local dealer. 8. Replace front bumper, using hardware removed in Step 3. WIRING INSTRUCTIONS: KFI #UTV-WEK OVERVIEW REQUIRED! Installation requires the use of KFI #UTV-WEK (Extended Wiring Kit). All wiring will first be routed from the hood compartment where the Contactor Block is mounted through a small wiring outlet (E), then either to the battery or the winch. Leave all ends loose until instructed to connect them. You will then work your way back to the front while securing wires to the frame and pulling slack into the hood compartment. INSTALL CONTACTOR 9. Position and install the Contactor Block to the preferred location as shown in Figure 5. It must be placed as in the photo to avoid radiator hoses directly below the plastic. Use the dotted lines as a guide and visually center the Contactor Block as shown in Figure 5. Install using hardware included with your winch, or alternatively, short drywall/multi-purpose screws. ROUTE WINCH WIRES 10. Feed the shortest wires included with your winch (usually RED & BLACK) from the hood compartment, through a wire outlet (E) as shown in Figure 5. Figure - 5: Hood Compartment Passenger Side 11. Run the winch wires down through the oulet, over top the passenger side shock support, and toward the Winch Motor end following the dashed path in Figure 6. RECOMMENDED WIRE PATH TO WINCH (Dashed) Inset: View of winch motor end. Figure - 6 Fan Radiator E Wire passing thru outlet (E) Shock Fig 6 - INSET Winch Motor View from passenger side, front end. 12. Loosely secure winch wires to the frame with zip ties, but do not fully tighten them to allow adjustment. 13. Per the ALTERNATE WINCH WIRING DIAGRAM (pg 5), connect the BLACK wire to the NEG (-) BLUE winch post; connect the RED wire to POS (+) YELLOW winch post. 14. Working your way back to the outlet (E), secure winch wires tight to the frame and push slack back into the hood compartment. DO NOT CONNECT to Contactor Block at this time. Copyright ©2014 - Kappers Fabricating, Inc. Page 2 of 6 B - 12/1/2014 INSTALL SWITCH 15. Use included Mini-Rocker Switch Hardware Kit (HK-031) to fasten a handle bar mounted mini-rocker switch to the dash or any desired location. a. Remove handlebar Figure - 7 mount hardware from the switch. b.Locate desired mounting location. c. Mark & drill 2 switch holes thru dash using switch housing as a template. d.Drill a 3rd hole for switch wiring. e. Assemble per Figure 7. 16. Connect the red ignition fed wire for a Mini-Rocker Switch or other controller to the orange terminal of the auxilliary wiring harness that is pre-installed on the passenger side in the front hood compartment. See Figure 8. Attach using the supplied 22-18GA Male Insulated Terminal. Wire to Contactor per your winch manual. Secure wires as needed. Figure - 8 Aux Hot Wire (Orange) 19. Before moving on to the next steps, tape off the YELLOW wire end left in the hood compartment with electrical tape for safety. You will be connecting these wires to the battery once they are routed properly, and this prevents arcing. Figure - 9 Figure - 10 E UTV-WEK Wires Front Differential Radiator + Fan Wire Bundle Wire Bundle FRONT FRONT Driver Side F 20. Locate a wire bundle (Figure 10) and follow its path under the vehicle. Route the UTV-WEK wires along this cable bundle (as shown in Figure 11) towards the rear of the vehicle to the battery compartment. Using zip ties, loosely secure the UTV-WEK wires to the wire bundle and pass it through the following key junction points: 21. Point F - Passing under the front differential (see Figure 10). FRONT Passenger Side F Driver Side WIRE BUNDLE G PATH E ROUTE BATTERY WIRES H **For 2018- current models, skip to step 29 You will route the wires from UTV-WEK to the battery along the same path as the parking brake wire bundle. (See Fig 11) 17. This vehicle requires extended 11FT battery wires included with the Wire Extension Kit (KFI#: UTV-WEK, sold separately). Use only the BLUE & YELLOW color coded wires found in UTV-WEK to connect the battery. 18. Feed the wires from #UTV-WEK through outlet (E) in the hood compartment shown in Figure 5, then down behind the fan, going from the passenger side strut support toward the driver side and the parking brake wire bundle as shown in Figure 9. K J L Figure - 11 View from below vehicle w/ skid plates removed. Copyright ©2014 - Kappers Fabricating, Inc. Page 3 of 6 B - 12/1/2014 G L Figure - 12 22. Point G - Through a wire hole in the plastic (see Figure 12). Figure - 15 Neg (-) Pos (+) (Remove Boot) H TUBE SUPPORT Figure - 13 23. Point H - Across and on top of a tube support (see Figure 13). J Hanger Figure - 14 K 24. Point J - Through a hanger (see Figure 14). 25. Point K - Special Note: KFI recommends using a 12" Wire Loom on the UTV-WEK wires in the location where the wires cross paths with the radiator lines at point (K). 26. Point L - Into the battery compartment; feed both ends of the wires from UTV-WEK, from under the vehicle, up through a hole found at location (L) directly above the wire bundle as shown in Figure 15. 27. Per the ALTERNATE WINCH WIRING DIAGRAM, attach the YELLOW wire to the screw on the POS(+) battery post. Attach the BLUE wire to the NEG(-) battery post. 28. Working your way back to the front hood compartment, pull wires taught and take out any slack as you go. Secure them with additional zip ties and tighten loosely placed zip ties from earlier steps. Note: Keep battery wires tight & secure against the wire bundle! DO NOT let them come in contact with any heat source or moving components! ROUTE BATTERY WIRES (2018-Current Models) 29. This vehicle requires extended 11FT battery wires included with the Wire Extension Kit (KFI#: UTV-WEK, sold separately). Use only the BLUE & YELLOW color coded wires found in UTV-WEK to connect the battery. 30. Before moving on to the next steps, tape off the YELLOW wire end left in the hood compartment with electrical tape for safety. You will be connecting these wires to the battery once they are routed properly, and this prevents arcing. 31. Remove the caps from the loom and feed the wires from #UTV-WEK through the wire loom in the hood compartment shown in Figure 16. *Note: It may be easiest to tape the ends of the 2 wires together so they do not get hung up while going through the loom. 32. From the battery compartment, you should be able to see the end of the wire loom, as shown in Figure 17. 33. Per the ALTERNATE WINCH WIRING DIAGRAM, attach the YELLOW wire to the screw on the POS(+) battery post. Attach the BLUE wire to the NEG(-) battery post. Copyright ©2014 - Kappers Fabricating, Inc. Page 4 of 6 B - 12/1/2014 COMPLETING INSTALLATION 34. In the hood compartment, finally connect the winch and battery wires to the Contactor Block per the ALTERNATE WINCH WIRING DIAGRAM shown on Page 5. Note: Remove the electrical tape from the YELLOW wire end applied in Step 19 before making connections! · Wire Winch NEG (BLACK WIRE) to BLUE Contactor post. · Wire Winch POS (RED WIRE) to YELLOW Contactor post. · Wire Battery NEG (BLUE WIRE) to BLACK Contactor post. · Wire Battery POS (YELLOW WIRE) to RED Contactor post. 35. If applicable, connect the small GREEN & BLACK wires from a Mini-Rocker switch or similar to the standard Contactor Block. Consult your Winch manual for specific wiring instructions. 36. Finish securing wires in the hood compartment, bundle up slack, and zip tie as needed. Replace the hood panel. 37. Replace skid plates removed in previous steps. 38. Replace battery compartment cover. Figure - 16 Figure - 17 Copyright ©2014 - Kappers Fabricating, Inc. Page 5 of 6 B - 12/1/2014 Note: Battery shown in this diagram represents a battery fed source. Depending on your vehicle configuration, power leads may attach to a primary/secondary battery or starter solenoid. Follow all vehicle specific installation instructions. Figure - 18 Copyright ©2014 - Kappers Fabricating, Inc. Page 6 of 6 B - 12/1/2014