Canopy Kit

Model No. 07141-Serial No. 400000000 and Up

Warning

CALIFORNIA

Proposition 65 Warning

This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.

Setup

Preparing the Machine

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Shut off the engine and remove the key.

  4. Remove the seats.

  5. Disconnect the battery; refer to your Operator’s Manual.

  6. Raise the cargo bed to the dump position and secure it with the prop rod.

Installing the Kit

Parts needed for this procedure:

Left loop bracket1
Right loop bracket1
Tube2
Left windshield support1
Right windshield support1
Left, rear plate1
Right, rear plate1
Left, front plate1
Right, front plate1
Left corner gusset1
Right corner gusset1
Rear crosslink1
Front crosslink1
Backing plate2
Crosslink tube2
Flange nut (5/16 inch)38
Flange nut (1/4 inch)4
Carriage bolt (5/16 x 1-3/4 inches)20
Hex-flange bolt (3/8 x 1 inch)4
Flange nut (3/8 inch)4
Hex-flange bolt (5/16 x 1 inch)2
Carriage bolt (5/16 x 1 inch)4
Clip4
Sunshade1
Sealing washer6
Hex-flange bolt (1/4 x 1 inch)6
Spacer (9/32 x 5/8 inch)2
Flat washer2
Hex-head bolt (1/4 x 2-1/2 inches)2
Mounting plate2
Carriage bolt (5/16 x 2 inches)8
Plastic washer4
Flange bushing2
Friction washer2
Carriage bolt (5/16 x 3/4 inch)4
Roof-support bracket2
Self-tapping screw (1/4 x 1/2 inch)2
Front support1
Hex-flange bolt (1/4 x 1-1/2 inches)2

Note: Do not tighten any fasteners except when instructed.

  1. Install the left loop bracket as follows:

    1. Remove the rivet from left panel behind the rear seat base (Figure 1).

    2. Install the left loop bracket using 2 hex-flange bolts (3/8 x 1 inch) and 2 nuts (3/8 inch) as shown in Figure 1.

      g036547

      Figure 1

      1. Rivet
      2. Nut (3/8 inch)
      3. Bolt (3/8 x 1 inch)

    3. Secure the bracket behind the rear seat base using 1 hex-head bolt (1/4 x 2-1/2 inches), 1 flat washer (5/16 inch), 1 spacer (9/32 x 5/8 inch), and 1 flange nut (1/4 inch) as shown in Figure 2.

      g036548

      Figure 2

      1. Flange nut (1/4 inch)
      2. Spacer (9/32 x 5/8 inch)
      3. Left loop bracket
      4. Hex-head bolt (1/4 x 2-1/2 inches)
      5. Flat washer (5/16 inch)

    4. Repeat this step to install the right loop bracket on the right side of the machine.

  2. Using the dimensions shown in Figure 3, drill 2 holes (5/16 inch) into the outside of the floor plate on the left and right sides of the machine.

    g036552

    Figure 3

  3. Using the dimensions shown in Figure 4, drill 1 hole (5/16 inch) into the outside of the footboard on the left and right sides of the machine.

    g036553

    Figure 4

  4. Secure the middle bracket of the windshield support to the machine using 2 hex-flange bolts (5/16 x 1 inch) and 2 nuts (5/16 inch) in the holes you drilled (Figure 5).

    g035381

    Figure 5

    1. Windshield support
    2. Hex-flange bolt
    3. Nut (inside dash frame)

  5. Secure the lower bracket of the windshield support to the left side of the machine using 4 carriage bolts (5/16 x 1 inch) and 4 flange nuts (5/16 inch) in the holes you drilled in step 2 (Figure 6).

    g036554

    Figure 6

    1. Carriage bolt (5/16 x 1 inch)
    2. Flange nut (5/16 inch)
    3. Lower bracket of windshield support

  6. Loosely install the rear tubes to the rear loop brackets using 8 carriage bolts (5/16 x 2 inches), 2 mounting plates, and 8 nuts (5/16 inch) as shown in Figure 7.

    g035014

    Figure 7

    1. Carriage bolt (5/16 x 2 inches)
    2. Mounting plate
    3. Nut (5/16 inch)

  7. Loosely install the left and right rear plates to the tubes using 4 carriage bolts (5/16 x 1-3/4 inches), 2 backing plates, and 4 flange nuts (5/16 inch) as shown in Figure 8.

    g036555

    Figure 8

    1. Carriage bolt (5/16 x 1-3/4 inches)
    2. Rear plate
    3. Backing plate
    4. Flange nut (5/16 inch)
    5. Tube

  8. Loosely install the left and right front plates and corner gussets to the crosslink tubes and the left and right windshield supports using 8 carriage bolts (5/16 x 1-3/4 inches) and 8 flange nuts (5/16 inch) as shown in Figure 9.

    g036560

    Figure 9

    1. Carriage bolt (5/16 x 1-3/4 inches)
    2. Front plate
    3. Corner gusset
    4. Flange nut (5/16 inch)
    5. Crosslink tube
    6. Windshield support

  9. Loosely install the rear crosslink to the crosslink tubes and rear plates using 4 carriage bolts (5/16 x 1-3/4 inches), 4 carriage bolts (5/16 x 3/4 inch), and 8 flange nuts (5/16 inch) as shown in Figure 10.

    g036668

    Figure 10

    1. Carriage bolt (5/16 x 3/4 inch)
    2. Rear crosslink
    3. Carriage bolt (5/16 x 1-3/4 inches)
    4. Flange nut (5/16 inch)

  10. Loosely install the front crosslink to the front plates and corner gussets using 4 carriage bolts (5/16 x 1-3/4 inch) and 4 flange nuts (5/16 inch) as shown in Figure 11.

  11. Install the front support to the front crosslink using 2 hex-flange bolts (1/4 x 1-1/2 inches) and 2 flange nuts (1/4 inch) as shown in Figure 11.

    g236328

    Figure 11

    1. Carriage bolt (5/16 x 1-3/4 inch)
    2. Flange nut (1/4 inch)
    3. Front support
    4. Flange nut (5/16 inch)
    5. Front crosslink
    6. Hex-flange bolts (1/4 x 1-1/2 inches)

  12. Tighten all loose fasteners.

  13. Install the 2 roof-support brackets to the crosslink tubes using 2 self-tapping screws (1/4 x 1/2 inch) as shown in Figure 12.

    g037011

    Figure 12

    1. Roof-support bracket
    2. Crosslink tube
    3. Self-tapping screw (1/4 x 1/2 inch)

  14. Set the sunshade down.

  15. Using the hole in the top of the roof-support bracket as the template, drill a 7.9 mm (5/16 inch) hole on each side of the sunshade (Figure 13).

    g037012

    Figure 13

  16. Install the sunshade to the roof-support bracket using 2 clips, 2 sealing washers, and 2 hex-flange bolts (1/4 x 1 inch) as shown in Figure 14.

    g037013

    Figure 14

    1. Sunshade
    2. Clip
    3. Hex-flange bolt (1/4 x 1 inch)
    4. Sealing washer

  17. Install the sunshade to the front plates using 2 clips, 2 sealing washers, and 2 hex-flange bolts (1/4 x 1 inch) as shown in Figure 15.

    Important: Apply thread-locking compound to the hex-flange bolts (1/4 x 1 inch) before installing.

    g035017

    Figure 15

    1. Hex-flange bolt (1/4 x 1 inch)
    2. Sealing washer
    3. Sunshade
    4. Clip
    5. Front plate

  18. Install the sunshade to the rear crosslink using 2 hex-flange bolts (1/4 x 1 inch), 2 sealing washers, 2 friction washers, 4 plastic washers, and 2 flange bushings (Figure 16).

    Important: Apply thread-locking compound to the hex-flange bolts (1/4 x 1 inch) before installing.

    Important: Ensure that the plastic washers are installed onto the top and bottom of the sunshade, as this prevents damaging the sunshade.

    g037077

    Figure 16

    1. Hex-flange bolt (1/4 x 1 inch)
    2. Sealing washer
    3. Friction washer
    4. Plastic washer
    5. Flange bushing
    6. Rear crosslink

  19. Connect the battery; refer to your Operator’s Manual.