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WORKSHOP MANUAL
All information in this manual is based on the latest product information available at
the time of publication. Therefore, some of the information in this manual may differ
from the machine you have.
KIOTI has a principle to apply update to the next edition of the manual if there is any.
However, KIOTI has no obligation to modify the contents in this manual, especially
the contents in the manual which is already distributed or published.
This manual is ultimately to satisfy customers with best performance of this UTV. If
there is any typo, wrong information or question for this manual, feel free to contact
KIOTI.
Apr. 2014
service division
DAEDONG INDUSTRIAL Co., Ltd.
Important REMARK
• Using unspecified parts, fuel and lubricants • We reserve the right to make changes
other than DAEDONG's genuine parts can throughout the entire manual at any time
damage the UTV and such damage will not be without notice.
covered by warranty.
CHAPTER 2 GENERAL
CHAPTER 3 ENGINE
CHAPTER 4 CVT
CHAPTER 5 TRANSMISSION
CHAPTER 6 CHASSIS
CHAPTER 8 BRAKE
CHAPTER 10 STEERING
CHAPTER 13 INDEX
TABLE OF CONTENTS
1.1 Alert symbols........................................... 1-2 2.5 Cautions when handling the battery........ 1-5
2.6 Cautions for high pressure hoses.................1-5
2. Safety tips........................................... 1-3
2.7 Use of appropriate tools and equipment 1-6
2.1 Safety gear.............................................. 1-3 2.8 Handling of hazardous materials................ 1-6
2.2 Workplace .............................................. 1-3 2.9 Handling of rotating shaft and driving belt........ 1-7
2.2.1 Ventilating system.......................... 1-3 2.10 Scald prevention..................................... 1-7
2.2.2 Safe workplace.............................. 1-3 2.11 Disposal of environmental waste..................1-8
2.2.3 Illumination.................................... 1-3 2.12 Cautions when handling tires.................. 1-8
2.2.4 Safety equipment........................... 1-3
3. Safety decals.................................... 1-9
2.2.5 Keeping your work area clean....... 1-3
2.3 Safety instructions when preparing UTV........ 1-4 3.1 The location of safety decal................... 1-9
1. SAFETY DECALS
매뉴얼
reaD 숙지 !
manual!
CVT
S76W001A
TRANSMISSION
A. Remark C. Caution
CHASSIS
REAR AXLE
Remark 주의
CAUTION
BRAKE
S76W002A S76W004A
• Broaden your knowledge with additionally supplied • This mark indicates potentially hazardous situation
FRONT AXLE
service information for optimal service. which, if not observed, may result in serious injury.
B. Important D. Warning
STEERING
HYDRAULIC
WARNING
ELECTRIC
S76W003A S76W005A
• This mark indicates emphasis on information which • This mark indicates hazardous situation which, if
can be confused when servicing. If this information not observed, may result in death or injury.
is not carefully read and observed, the UTV cannot
fully function or may be damaged.
INDEX
1- SUUV-W00
SAFETY FIRST
2. Safety tips
2.1 Safety gear 2.2 Workplace
GENERAL
ENGINE
S76W007A
CVT
2.2.1 Ventilating system
S76W006A The service should be performed in a well-ventilated
area. If the engine should be started in an enclosed
When operating on the vehicle, wear safety gloves, place, an exhaust gas vent pipe should be installed.
TRANSMISSION
safety shoes, ear plugs, safety goggles, safety helmet,
working clothes, etc. appropriate for your working envi- WARNING
ronment. 경고
• California Proposition 65 Warning
Never wear loose fitting clothing or a tie which can be
Inhaling exhaust gas can cause cancer or damage
caught by rotating part. According to the statistics, most
CHASSIS
the generative function leading to infertility.
accidents occurred with rotating parts are due to this
inappropriate manner of wearing clothes.
2.2.2 SAFE WORKPLACE
REAR AXLE
BRAKE
FRONT AXLE
S76W008A
2.2.3 Illumination
The work place should be well illuminated. If working in
a dark place or under the vehicle, use the work lamp.
The work lamp should be covered with the safety cov-
HYDRAULIC
er. The bulb can start a fire due to the leaked fuel when
it is broken.
ELECTRIC
Keep the working area clean before and during work. If any
oil or fuel is spilled, it should be cleaned up immediately.
SUUV-W00 1-
S76W011A
S76W012A
CHASSIS
S76W013A
•
• Always disconnect the battery cable for fire preven-
tion before wiring service.
• Be extra cautious of fire when welding.
STEERING
HYDRAULIC
ELECTRIC
S76W014A
1- SUUV-W00
SAFETY FIRST
2.5 Cautions when handling the 2.6 Cautions for high pressure hoses
battery
GENERAL
ENGINE
S76W019A
S76W015A
• The hydraulic fluid leaks from high pressure
• Always disconnect the negative battery cable first hoses or pipes can penetrate your skin.
CVT
and reconnect it last to avoid sparks from an acci-
dental short circuit. Otherwise, it could result in fire
or injury.
TRANSMISSION
CHASSIS
REAR AXLE
S76W020A
• Do not charge the frozen battery. Charging the fro- ter the hydraulic system service.
BRAKE
zen battery can cause explosion. Let the battery • Use a cardboard or plank when checking leakage.
warm up to ambient temperature (16°C, 60°F) be-
fore charging.
• Keep sparks and flames (match, lighter) away from
FRONT AXLE
the battery. The battery can explode due to hy-
drogen gasses inside the case.Never connect the
battery's negative and positive cables with metal
for test. Use only tester when checking. the battery
voltage.
STEERING
HYDRAULIC
S76W021A
S76W018A
SUUV-W00 1-
its tightening torque should be strictly followed. It • These materials should be rinsed or wiped away
can cause malfunctions. after sprayed with oil.
• Be careful of a socket popped out due to the turning
force when using the air impact wrench. Especially,
be extra cautious when working on connection or
CVT
S76W022A
•
hoist, fix it firmly and install the auxiliary support.
Never work under the tractor if the support and the
hydraulic jack (hoist) are not installed.
FRONT AXLE
ous accident.
• Check the buttons and operating direction of the
hoist before using it. Improper operation can cause
a serious accident.
HYDRAULIC
1- SUUV-W00
SAFETY FIRST
2.9 Handling of rotating shaft and 2.10 SCALD PREVENTION
driving belt
GENERAL
ENGINE
S76W024A
S76W027A
• Do not set a hand or a foot into the vehicle’s rotat-
CVT
ing shaft or belt. • Do not open the radiator cap when the radiator is
• Be extra careful when you are in loose clothes. hot. Hot coolant or steam can be surged leading to
a serious scald.
TRANSMISSION
CHASSIS
REAR AXLE
S76W025A
BRAKE
S76W028A
FRONT AXLE
There is a high risk of burning.
• Perform any service on the engine parts (muffler,
exhaust manifold, etc.) only when they are not hot.
STEERING
S76W026A
HYDRAULIC
SUUV-W00 1-
S76W029A S76W030A
• Observe relevant environmental protection regula- • The tire rims can fall out of the tires. Therefore, stay
TRANSMISSION
tions when disposing used oil, transmission fluid, out of its way when checking or inflating tires.
coolant, oil filter, etc. Otherwise, they can pollute the
environment seriously and you could be charged in
violation of regulations.
CHASSIS
REAR AXLE
BRAKE
S76W031A
1- SUUV-W00
SAFETY FIRST
3. Safety decals
• When replacing the existing part with a new one, attach the same safety decal to the new part. Otherwise, the
customer's safety will be threatened.
• If a decal is damaged or detached, attach the same decal to the part.
GENERAL
• The decals and their attaching locations are as follows.
• There is part number on the bottom of decals.
ENGINE
5
CVT
4 14
17 6 4 8
18
9
TRANSMISSION
11
12
CHASSIS
REAR AXLE
BRAKE
19
FRONT AXLE
STEERING
HYDRAULIC
2
1 1 7 15 13
ELECTRIC
3
16 10
UT3W101B
INDEX
SUUV-W00 1-
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GENERAL
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ENGINE
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CVT
TRANSMISSION
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CHASSIS
REAR AXLE
TO PREVENT PERSONAL
INJURY,
BRAKE
holds.
2. Do not remove the ROPS for
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any reason.
3. Never modify or alter the ROPS.
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STEERING
1. Do not start engine by shorting across starter terminals or bypassing the
safety start switch. The vehicle may start in gear and move if normal
ELECTRIC
1-10 SUUV-W00
SAFETY FIRST
GENERAL
· Do NOT Carry passengers/riders in the bed
· Do NOT travel with the cargo bed in the raised position
· Do NOT exceed the rated bed capacity of 1,100 pounds (500 Kg)
· Do NOT Place hands behind the seat or underneath the cargo bed when lowering.
· When hauling or towing, always reduce speeds and increase braking zones to
prevent accidents
· When hauling or towing navigate turns and rough or uneven terrain at reduced speeds
ENGINE
· DO NOT haul or tow unsecured loads or cargo.
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CVT
(7) Part No. : U3215-85711 (8) Part No. : U3215-85601
TRANSMISSION
%#76+10 CAUTION
61#81+&+0,74;(41/%475*+0) TO PREVENT DRIVETRAIN DAMAGE:
1. The selective control valve lock is designed to
· Do not shift ranges with the engine
prevent accidental engagement of the hydraulic
CHASSIS
dump or remote valve only. RPM's above idle
2. NEVER rely on the selective control valve lock to
prevent accidental bed lowering when performing · Do not shift ranges while the vehicle is
maintenance on a vehicle equipped with a hydraulic moving
dump.
REAR AXLE
3. ALWAYS make sure a KIOTI approved bed prop or
· Do not engage the rear differential lock
cylinder lock is in place before performing
maintenance underneath a raised bed.
while the machine is moving
U3215-85711 |ZYX\T_\]WX
BRAKE
(9) Part No. : U3215-85621
FRONT AXLE
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STEERING
1. If equipped with manual dump, the bed prop should be locked in the fully raised position.
2. If equipped with hydraulic dump, the cylinder lock should be securely fastened around the fully
extended lift cylinder. ݃ܟܠܤܣܦܛܣܟܠܡ
ELECTRIC
INDEX
SUUV-W00 1-11
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1. The owner's manual and warning labels contain important information on �����������������������������������
safe operation of this vehicle. You must read and fully understand the ������������������������������
GENERAL
owner's manual and warning labels before operating this vehicle. Do not lock differential or turn with
2. Use on public road is hazardous. differential locked while operating
This vehicle is designed and equipped for off-highway use only. machine at high speed or on slopes
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3. Children may not have the skills and judgement to safely operate this vehicle.
All operators should possess a valid driver's license or be 16 years of age or older.
4. Carrying passengers outside the passenger compartment can be hazardous.
ENGINE
This vehicle is designed to carry the operator and a maximum of two additional
passengers in the seat provided.
5. Protective head gear reduces the risk of head injuries.
Use of helmet in rough terrain and a hard hat at construction sites is
especially recommended.
6. Seat belts reduce injuries. Always fasten your seat belt.
7. Alcohol and drugs impair reaction time and judgement.
CVT
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REAR AXLE
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(185MM)
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BRAKE
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FRONT AXLE
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STEERING
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HYDRAULIC
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ELECTRIC
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1-12 SUUV-W00
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