Owner s Manual Model: Kawasaki Teryx 2 Kawasaki Teryx 2 Cab Kit* Caution: efore using this product, read this manual and follow all Safety Instructions. Safety Instructions Cab Kit Contents Hardware ssembly Panel ssembly Operation *DefenderCab and accessories are in no way affiliated With Kawasaki Heavy Industries Ltd. ny use of the name is only to identify their utility vehicle as it pertains to our accessories. Kawasaki and Teryx are registered trademarks of Kawasaki heavy industries Ltd. 1
Warning: Failure to heed all safety and operating instructions and warnings regarding use of this product can result in serious bodily injury. SFETY INSTRUCTIONS Read entire assembly instructions before beginning work. Install all parts indicated in assembly instructions. Failure to fully assemble product before use could result in personal injury. ssembly of product requires use of hand or power tools. If you are not experienced in using these types of tools, have product dealer do the installation for you. Some parts contain sharp edges as indicated in the manual. Wear protective gloves if necessary. Dress for safety. DO NOT wear loose clothing, gloves, neckties or jewelry if using power tools to assemble this product. lways keep your assembly area clean, uncluttered and well lit. Keep visitors and children a safe distance away from the assembly area. Visitors should wear the same safety equipment described above. Never operate your TV with the cab doors open. Failure to properly latch the doors before moving the vehicle could result in serious injury. 2
C KIT CONTENTS Your DefenderCab should contain the parts listed below. Separate all parts from packing materials. Do not discard packing material until assembly is complete. Item quantities are listed in parenthesis below. Hardware Panels, Doors and rackets (2) 1 ¾ Clamps (1) Windshield Panel (2) Door Lever Knobs (1) ack Panel ssembly (2) Windshield Spacers (1) L-H Front Door ssembly (1) 25ft Roll, Hard Gasket (1) R-H Front Door ssembly (1) 25ft Roll, Soft Gasket (1) L-H Front Filler (8) Door ushings (1) R-H Front Filler (1) Hardware ag (1) L-H Door Upper Filler (96 ) Edge Trim 5/8 ulb (1) R-H Door Upper Filler (2) Door Frame umpers (2) Face Plate (1) R-H Front Door Lever (1) L-H Front Door Lever 3
Hardware bag will contain: 1/4-20unc 3/4" lg button head socket cap, SS 5 1/4-20unc 1/2" lg button head socket cap, SS 42 10-32unc 1" lg button head socket cap, SS 2 10-32 Nylon lock nut 2 Washer.26" i.d.55" o.d Stainless steel 30 Washer.406" i.d -.875" o.d Stainless steel 36 ond seal galvanized washer #14x5/8 small i.d 23 1/4-20 Nylon Lock Nut 2 1/4-20 Flanged lock nut 10 M6x1.00, 8mm, Pan Head Phillips Screw, Zinc Plate 2 M6x1.00, 16mm, Pan Head Phillips Screw, Zinc Plate 4 5/16-18 x 3/4" flanged bolt 4 5/16-18 x 1 3/4" Hex Cap Screw 8 5/16-18 hex reg nut 8 5/16-18 Heavy Nyloc Nut, Ylw. Zn. Pl. 12 Push Type Retainer, 1/4", Phillips,LCK 16 #8 x 1/2" Sheet Metal Screw, Truss Head, Phillips, 12 5/32" short arm hex key 1 1/8" short arm hex key 1 1/2" Yellow flat washers 4 1/4-20unc 2 1/4" lg button head socket cap, SS 2 1/4 x 1'' fender washer ss 2 1/4" flat washers, zinc 8 TOOLS REQUIRED FOR SSEMLY Ensure that you have the following tools available before you begin the assembly of your DefenderCab kit. Note: ssembly requires an assistant. Phillips & Flat Screwdrivers Ratchet set, ¼, 3/8, ½ 5/32 llen Wrench Metric and standard socket set Compact drill/driver 1/4 drill bit Utility knife Utility Clamps or Locking Pliers Rubber Mallet ar Clamps Dremel tool or die grinder 4
Kit Installation 1. Windhield Panel Install I) Loosely install the (2) 1 ¾ rubberized clamps onto top rollcage at approximate locations shown (Fig.1). Ensure tabs on panel clamps are pointing towards the interior of the vehicle. (Optional wiper package shown) Fig.1. 2014-2015 V) Install the L-H Front Filler and the R-H Front Filler to the bottom front roll bar using (4) M12x1.5, 80mm flanged hex bolts black [], (12) ½ yellow flat washers [] and the (4) existing OEM nuts [C]. (fig.4) (Current front fillers have slotted holes) 2016 & Up These filler attache using the existing bolt. Only using (4) ½ yellow flat washers [] On the inside and OEM Nuts Fig.4 C 5
VI) Re-install windshield panel onto vehicle. Fasten panel with (2) #10-32unc 1 long button head socket cap [], (2) 10-32 nylon lock nuts [] and (2) windshield spacers [C] (Fig.5) ensuring windshield panel sits firmly onto foam gasket strip. C Fig.5 VII) fter installing the windshield, fasten the windshield panel to the front fillers using (4) 5/16-18 x ¾ long flanged bolts [], (4) 5/16-18 heavy nyloc nut yellow zinc Plated [] and (4) washers 0.406 i.d. 0.875 o.d. stainless steel [C] (fig.6) The windshield panel install is now complete. Fig.6 C Roof Trim Install V) Install a length of edge trim (5/8 bulb) along the roof side edges as shown, starting from the front working your way to the rear. (fig.12) Fig.12 6
Fig.13 VI) Cut the edge trim (5/8 bulb) at the desired length, ensuring you have it flush against the back panel (fig.13) ack Panel Installation Fig.14 First we need to prepare the side by side for the back panel. Remove both seat covers by unclipping the front and pulling upwards. Remove the 4 bolts holding seat down (fig.14). Once the seat is removed you may remove the side panel s inbetween the rear roll bar and dump box (fig.15). Turn clip seen in (fig.16) to remove this panel. Fig.15 Now we are ready to install the Rear Lower panel slide in the panel behind the cross roll bar and push the bottom of the panel until it hold on the floor lip (fig.17). Fig.16 Fig.17 7
Fig.18 Secure lower panel with Rear panel attachement brackets using 1/4-20unc 2 1/4" lg button head as shown in Fig. 18. dd trim to side of rear panel where it meets the rollbar. Next step is to put loosen the top OEM bolt from Cross roll bar and slide in our rear attachement brackets into slots and lining up with the panel. Using ¼ -20 1/2" lg button head, Washer.26" i.d.55" o.d Stainless steel and 1/4-20 Flanged lock nut. ttachethe rear upper side panels to the lower panel and attachement bracket.secure top of side panel using ¼ -20 1/2" lg button head with 1/4 x 1'' fender washer ss and 1/4-20 Flanged lock nut (fig. 21). Fig.18 The back upper back panel maybe be installed to the lower and side panels using (17) ¼ -20 1/2" lg button head and (17) ond seal galvanized washer. The rear upper panel can be pushed upward 8
Door Install (Front and Rear, Left and Right door installations will be the same. General door instructions will be detailed once.) Fig.14 I) Remove doors from factory mounting points by removing the original bolts (4 per door). (fig.14) Place doors on a workbench or table for ease of work. Defender Cab doors will be mounted on existing factory doors. II) Steadily line up face plate with the extrusion on the interior side of the door and mark the locations of the 8 holes. lso mark the triangle in the middle of the face plate. Drill each hole using a ¼ drill bit and cut out the center hole with a dremel tool or die grinder. e careful not to drill or cut too far as it is easy to go through both sides of the door or hit the inner latching mechanism. Fig.15 III) Insert (8) push type retainers, ¼, phillips, black [] in the holes to hold the face plate in place. (fig.15) 9
(Ignore the door lever in fig.15) IV) Tap in the (4) door bushings into the door hinge holes, (fig.16a) making them flush with the hole on the exterior side of the door. (fig.16b). Fig.16a Fig.16b V) Insert (4) washers 0.406 i.d. 0.875 o.d. stainless steel [] (one per hole, fig.17a) and (4) 5/16-18 x 1 ¾ long hex cap screws [] (fig.17b) on the outer side of the door. Fig.17a Fig.17b VI) Take the door and place it on the factory hinges of the TV. (fig.18a) Then place (4) washers (0.406 i.d. 0.875 o.d. stainless steel) [] on the other side of the hinge (fig.18b). Fig.18a Fig.18b 10
Fig.19 VII) Tighten (4) reg hex nuts [] onto the 5/16-18 bolt from step VI then place (4) more washers (0.406 i.d. 0.875 o.d. stainless steel) [] on the other side of the nut. (fig.19) VIII) Slide the (4) knobs [] onto the (4) door levers []. Fig.20 On the lower door assembly, use the most rearward hole for the right hand side levers and use the forward hole for the left hand side levers (fig.20) for installation. Left lever s hole Right lever s hole D Install the door levers on the lower door frames bolted in this order: (1) ¼-20unc ¾ long button head socket cap [C], (1) 0.26 i.d. 0.55 o.d. SS washer [D], (1) lower door frame [E], (1) same size washer [D], (1) door lever [], (1) same size washer [D] and (1) ¼-20 nyloc nut [F]. Fig.21 11 C E F
Fig.22 ll door levers are different for each corner. The figure below will show which lever goes to which corner. (fig.22) (Left levers are push to open while right levers are pull to open) IX) Install bumper to lower door frame where shown (fig.23a) using (1) M6x1.00, 8mm pan head Phillips screw [], (1) ¼ flat zinc washer [] and (1) door frame bumper [C] (fig.23b). Fig.23a C Fig.23b 12
X) Place the lower door frame assembly onto the door having the extended end of the door lever going into the door latch. (fig.24) Fig.24 XI) Place (4) 0.406 i.d. 0.875 o.d. stainless steel washer [] onto the 5/16-18 bolts from step VI (fig.25a) then loosely place (4) 5/16-18 yellow zinc plated heavy nyloc nuts [] onto that same bolt. (fig.25b) Fig.25a Fig.25b XII) Place (2) M6x1.00, 16mm, pan head phillips screw, zinc plate [] and (2) ¼ zinc flat washers [] in the slots of the lower door frame assembly and lossely fasten into the door (fig.26). djust the lower door frame assembly the the desired position where the door can close with no interference (approx. middle of the slot). Tighten the screws from this step and the nuts from step X. lso adjust and tighten the door frame bumper from step IX to the desired height. 13 Fig.26
XIII) Place the upper door frame assembly on top of the lower door frame assembly ensuring the seal under the window is against the outside of the plastic door. Place and tighten (5) ¼-20 x ½ long button head socket cap screws [] and (5) 0.26i.d. 0.55 o.d. wahsers [] into the existing pem nuts to fasten the door assemblies together. (fig.27a). Fig.27a XIV) Insert (2) ¼-20 x ½ long button head socket cap screws [], (2) 0.26i.d. 0.55 o.d. wahsers [] and (2) ¼-20 flanged lock nuts [C] to serve as adjustment for the upper door frame s angle (fig27b). Tilt the upper door frame inward until the top of the door is tight against the roll bar when closed. Tighten when adjustment has been completed. Fig.27b C 14
XV) Install the door crossmember caps by placing them over the crossmembers (middle of lower door frame) using (6) #8 x ½ sheet metal screws, truss head, Phillips. [] (fig.28) Fig.28 This concludes the door installation. Repeat steps I through XV to complete each door. Using the 3 ack panel clips provided you may fasten the back panel to the roof. Using bondseal washers and 1/4x20 bolt and nut drill thru the roof and fasten to rear panel. 15
OPERTION The DefenderCab is very useful for work or play. It is perfect for the hunting, farming, fishing, commercial and recreational enthusiast. The cab and optional wipers allow the full enjoyment of the vehicle in all weather conditions. Cleaning your DefenderCab Use same mild soap and techniques used to clean your TV To order replacement parts, contact the Parts Department at: L Manufacturing Inc. 247 rsenault Road, Dieppe, N. Canada E1 7J5 Ph: (506) 388-9334 Fax (506) 388-3325 www.defendercab.com parts@defendercab.com Manual Revision: 1.0 Date: ugust 11, 2016 16