Kawasaki Mule 4010 Road Lighting Kit Fitting · PDF...

!!!
!
www.quadtech.co.uk!
!KAWASAKI!MULE!
ROAD!LIGHTING!KIT!!
FITTING!INSTRUCTIONS!!
!!
This!instruction!booklet!covers!step!by!step!the!installation!of!a!lighting!kit!on!a!Mule!4010!
Page!7!explains!the!differences!when!fitting!a!kit!to!a!Mule!600!or!3000!series.

Kawasaki!Mule!Road!Lighting!Kit!Fitting!Instructions!!!
2/8!
www.quadtech.co.uk
The!kit!includes!the!core!items!required!to!modify!a!Kawasaki!Mule!4010!to!meet!the!lighting!section!VOSA!single!vehicle!approval!standards.!
!
! !!Parts!in!the!kit:! Front!Indicators! Front!Sidelights! Rear!Tail/Brake/Indicator!lamps! PlugWandWplay!wiring!harness! Steering!column!mounted!control!switch!with!controls!for!headlights,!indicators!and!hazards.! Dashboard!warning!lamps!for!indicators!and!main!beam! Indicator!Relay! Numberplate!bracket!&!lamp(optional)! 7!pin!UK!spec!trailer!socket!(optional)!!Remove!under!seat!panels!and!floor!cable!ducts!!both!front!and!rear!on!Trans.!
!Remove!front!storage!box!for!access!to!the!back!of!the!dashboard!!Remove!headlamp!&!grille!panel!!Numberplate!lamp!!Mount!a!square!numberplate!onto!the!top!right!corner!of!the!roll!cage.!Drill!mounting!holes!in!the!top!centre!of!the!plate!to!mount!the!numberplate!lamp!onto!the!numberplate.!

3/8!
www.quadtech.co.uk
Route!the!rear!cable!harness!alongside!the!OEM!cables!both!in!the!engine!area!and!through!the!cable!duct.!
!The!6!pin!connector!at!the!front!of!the!harness!should!end!near!the!pedals.!!The!ring!terminal!on!the!white!wire!connects!to!the!battery!+ve!3!pin!white!triangular!connector!at!the!back!connects!where!the!OEM!tail!lights!would!connect.!
!If!using!high!level!numberplate!&!tail!light!location:! Remove!tail!lights!and!brackets! Mount!tail!light!board!on!the!cab!rear!grille!and!route!cable!down!to!the!4!pin!black!and!
white!plugs!on!the!rear!harness!!If!fitting!tail!lights!in!the!Kawasaki!recommended!location:! Remove!tail!lights!from!OEM!brackets! Fit!new!tail!light!with!black!plug!to!the!
original!left!bracket! Fit!new!tail!light!with!white!plug!to!the!
original!right!bracket! Hold!tail!light!cables!in!place!using!
original!cable!clamps!!Plug!the!4!pin!plugs!from!the!tail!lights!into!the!Black!and!White!connectors!on!the!rear!harness.!!The!2!bullets!are!to!connect!to!a!numberplate!lamp!(if!necessary)!

4/8!
www.quadtech.co.uk
!The!6!pin!translucent!socket!and!bullet!are!for!connection!to!the!7!pin!trailer!socket!which!can!be!bolted!to!the!frame!!NOTE:!The!harness!is!long!enough!to!reach!the!tail!lamps!on!a!TRANS.!On!a!standard!length!mule!will!be!necessary!to!route!the!cable!in!a!loop!under!the!seat!!Front!Harness:!!Lay!the!harness!into!the!cable!area!with!the!6!pin!translucent!waterproof!plug!positioned!near!the!pedals.!Connect!6!pin!plug!to!the!rear!harness.!!Quadtech!Control!Switch.!!
The!control!switch!is!clamped!to!the!steering!column.! 2!rubber!strips!are!supplied!to!securely!mount!the!switch,!giving!a!small!amount!of!
movement!to!ensure!no!damage!in!the!incidence!of!an!impact.! Remove!the!4!allen!bolts!from!the!switch! Lay!the!2!pieces!of!rubber!on!top!of!eachother!and!insert!into!the!switch!with!the!top!of!the!
rubber!in!line!with!the!top!of!the!plastic.! Fit!the!left!half!of!the!switch!to!the!steering!column,!wrap!the!rubber!strips!around!the!right!
hand!size!and!fit!the!right!clamp.! Plug!9!pin!plug!into!Quadtech!Harness!!

5/8!
www.quadtech.co.uk
Headlights.!!Remove!rectangular!headlamp!cowl!from!the!grille!panel!and!drill!2!x!20mm!holes!in!each.!There!is!space!in!each!corner!for!the!holes,!this!photograph!shows!an!example!location.!!Mount!one!sidelight!and!one!indicator!in!each!headlamp!cowl!!slip!the!rubber!bezel!off!the!lamp,!insert!the!cable!through!the!hole,!locate!the!bezel!onto!the!plastic!and!then!push!the!lamp!into!the!bezel!ensuring!the!word!TOP!is!at!the!top.!
Refit!the!headlamp!cowls!to!the!grille.!!Headlamp!connections:!The!long!wires!with!2!pin!sockets!and!spade!connector!are!to!connect!the!headlamps.!
! Route!the!long!wire!with!orange!wire!to!
the!right!headlamp,!and!purple!wire!to!the!left!lamp.!
Remove!the!white!clips!on!the!headlamp!plugs.!
Remove!the!rubber!bung!in!the!central!terminal!hole.!
Insert!the!terminal!on!the!green/black!wire!into!the!hole!and!push!into!place!with!a!small!screwdriver.!ENSURE!that!the!terminal!is!inserted!the!same!way!round!as!the!other!2!terminals.!
! Refit!the!headlight!grill.!Reconnect!the!3!pin!plugs!for!the!headlamps!and!connect!the!2!pin!
plugs!for!the!indicators!&!sidelights!into!their!matching!connectors.!

6/8!
www.quadtech.co.uk
Headlamp!switch! Unplug!the!grey!6!pin!plug!on!the!OEM!headlamp!switch! Plug!this!into!the!Quadtech!Harness!grey!6!pin!socket! Plug!the!Quadtech!harness!grey!6!pin!plug!into!the!OEM!6!pin!socket!where!the!headlamp!
switch!was!previously!connected.!!Unplug!the!wire!going!to!the!speedometer!backlight!to!the!OEM!harness!and!plug!into!the!identical!connector!on!the!Quadtech!Harness!instead.!
!!Mount!the!hazard!and!indicator!relays!on!the!flat!panel!behind!the!headlight!switch.!!Mount!the!warning!lamps!through!the!dash!panel!and!connect!to!the!cable!harness.!!Completion:!!Test!the!operation!of!:! Indicators!&!hazards! dip/main!beam!of!headlamps! tail/brake!of!rear!lights.! Numberplate!lamp.!!Refit!floor!cable!ducts!and!under!seat!panels.!Refit!front!storage!box.!

7/8!
www.quadtech.co.uk
MULE!3010!!Fit!the!kit!exactly!as!MULE!4010!except!for!headlights!and!additional!front!lights.!!At!the!front!unplug!the!Red/Black!wire!from!the!headlight!and!connect!to!the!Black/Green!wire!on!the!Quadtech!harness.!!Connect!the!Red/Yellow!wire!coming!from!the!headlight!to!the!Red/Black!wire!on!the!original!Mule!harness.!!MULE!600!series!!At!the!rear!unplug!the!original!tail!light.!Plug!Blue!bullet!previously!connected!into!tail!light!into!Blue!wire!on!Quadtech!harness.!An!additional!Kawasaki!Lamp!holder!will!be!required!for!the!right!hand!side.!!Remove!the!headlight!!Change!connections!as!below!!
!!Drill!52mm!hole!in!dashboard!and!fit!Acewell!MD52!speedometer.!Plug!speedometer!into!connections!on!Quadtech!harness.!Fitting!instructions!for!the!speedometer!are!in!the!speedometer!box.!

8/8!
www.quadtech.co.uk
!www.q
uadtech.c
o.u
kSW
ITCH
ED +
VE
+VE
-VE
SID
E / T
AIL
DIP
PED
BEA
M
BRAK
E
LEFT
RIG
HT
IND
RET
URN
IND
LIV
E
MAI
N B
EAM
HAZA
RD C
ONTR
OL
HAZA
RD SW
ITCH
FOG
Br W B/Y R B/G L V O B/W
W/B
G/B L/Y
Y/L
R/B
QT-
SXS-
MU
LEKA
WAS
AKI M
ULE
LIG
HTI
NG
HAR
NES
S
Conn
ecto
rs c
hang
es fo
llow
ing
test
ing
29/1
0/12
3 4
3
11
1
4
3
1
4
2
2
3 7
4 6
3 8
4 6
3
13
11
9
1
2
8
4
5
7
3 7
5
Colu
mn
Mou
nt
Cont
rol S
witc
h
Opt
iona
l Fog
lig
ht S
witc
h
Conn
ect I
nlin
e to
H
eadl
ight
Sw
itch
Spee
dom
eter
bac
klig
ht
Acew
ell S
peed
opo
wer
con
nect
ion
War
ning
lam
ps
Ora
nge
wire
right
war
ning
lam
p
Purp
le w
irele
ft w
arni
ng la
mp
Blac
k/G
reen
wire
high
bea
m w
arni
ng la
mp
Haz
ard
and
Indi
cato
r Rel
ay
5
Righ
t ind
icat
or
front
win
g re
peat
er
Righ
t Sid
elig
ht
Righ
t Ind
icat
or
Righ
t Hea
dlig
ht
Left
Indi
cato
r
Left
Sid
elig
ht
Left
Hea
dlig
ht
Left
indi
cato
r fro
nt w
ing
repe
ater
Blac
k pl
ug, L
eft T
ail L
ight
Whi
te p
lug,
Rig
ht Ta
il Li
ght
Conn
ect i
nto
whe
re o
rigin
al ta
il lig
ht h
arne
ss c
onne
cted
Opt
iona
l Fog
Lig
ht
Num
berp
late
Lam
p
Batt
ery
+ve
Opt
iona
l Tra
iler S
ocke
t
Colo
urFu
nctio
n
12
3 5 8 73 3
13 1
7 18
7
8
2
12
1
3
7 8
2
8 7
1115 1
65
Dip
/ M
ain
beam
head
light
setu
pbu
llet c
onne
ctio
ns

Kawasaki Mule 4010 Road Lighting Kit Fitting · PDF...

Documents

Transcript of Kawasaki Mule 4010 Road Lighting Kit Fitting · PDF...