Ezgo 1600xd Mode d'emploi

ISSUED APRIL 2011

1600xd

4x4

repair

manual

619728

We reserve the right to make changes

throughout the entire manual at any time

without notice.

•

REMARK

Using unspecified parts, fuel and lubricants

other than DAEDONG's genuine parts can

damage the UTV and such damage will not be

covered by warranty.

•

IMPORTANT

PREFACE

This manual is to provide servicing personnel with information on the general speci-

ﬁcations, service, operating principle, troubleshooting, exploded view including part

name, removing and installing procedures for OFF - ROAD Utility Vehicle with high-

end technology.

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.

We have a principle to apply update to the next edition of the manual if there is any.

However, We have no obligation to modify the contents in this manual, especially the

contents in the manual which is already distributed or published.

The modiﬁed information is available in our online electronic manual system (DEMSS).

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

us.

Apr. 2011

service division

DAEDONG INDUSTRIAL Co., Ltd.

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CHAPTER 1 SAFETY FIRST

CHAPTER 2 GENERAL

CHAPTER 3 ENGINE

CHAPTER 5 TRANSMISSION

CHAPTER 6 CHASSIS

CHAPTER 7 REAR AXLE

CHAPTER 8 BRAKE

CHAPTER 10 STEERING

CHAPTER 9 FRONT AXLE

CHAPTER 11 HYDRAULIC SYSTEM

CHAPTER 4 CVT

CHAPTER 12 ELECTRIC SYSTEM

TABLE OF CONTENTS

CHAPTER 13 INDEX

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CHAPTER 1

TABLE OF CONTENTS

SAFETY FIRST

1. SAFETY DECALS................................... 1-2

1.1 Alert symbols..........................................1-2

2. SAFETY TIPS.......................................... 1-3

2.1 Safety gear.............................................1-3

2.2 Workplace .............................................1-3

2.2.1 Ventilating system.........................1-3

2.2.2 Safe workplace.............................1-3

2.2.3 Illumination ...................................1-3

2.2.4 Safety equipment..........................1-3

2.2.5 Keeping your work area clean......1-3

2.3 Safety instructions when preparing tractor...1-4

2.4 Fire.........................................................1-4

2.5 Cautions when handling the battery.......1-5

2.6 Cautions for high pressure hoses ..........1-5

2.7 Use of appropriate tools and equipment...1-6

2.8 Handling of hazardous materials............1-6

2.9 Handling of rotating shaft and driving belt.....1-7

2.10 Scald prevention ....................................1-7

2.11 Disposal of environmental waste ...........1-8

2.12 Cautions when handling tires.................1-8

3. SAFETY DECALS................................... 1-9

3.1 The location of safety decal ...................1-9

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1-2 SUUV-W00 Apr. 2011

SAFETY FIRST

GENERALENGINECVT

TRANSMISSION

CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX

1. SAFETY DECALS

Most accidents can be avoided if basic safety in-

structions and regulations are followed. Always fol-

low the safety regulations and avoid any dangerous

situation to prevent an accident.

You can be unexpectedly injured if inspecting or

servicing the UTV without full knowledge of it. Read

the manual carefully before starting service, and

follow the instructions on service, maintenance and

inspection to prevent any injury.

•

1.1 ALERT SYMBOLS

The meanings of the safety-alert symbols used in this manual are as follows:

A. REMARK

Broaden your knowledge with additionally supplied

service information for optimal service.

•

S76W002A

REMARK

C. CAUTION

This mark indicates potentially hazardous situation

which, if not observed, may result in serious injury.

•

ܙ#ڬ

S76W004A

CAUTION

S76W003A

B. IMPORTANT

This mark indicates emphasis on information which

can be confused when servicing. If this information

is not carefully read and observed, the UTV cannot

fully function or may be damaged.

•

D. WARNING

This mark indicates hazardous situation which, if

not observed, may result in death or injury.

•

S76W005A

WARNING

κȷ#դܹ#$

S76W001A

READ MANUAL!

SAFETY FIRST - SAFETY DECALS

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SUUV-W00 Apr. 2011 1-3

SAFETY FIRST

GENERALENGINECVT

TRANSMISSION

CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX

경고

S76W007A

S76W008A

2. SAFETY TIPS

2.1 SAFETY GEAR

2.2.1 VENTILATING SYSTEM

The service should be performed in a well-ventilated

area. If the engine should be started in an enclosed

place, an exhaust gas vent pipe should be installed.

2.2.2 SAFE WORKPLACE

California Proposition 65 Warning

Inhaling exhaust gas can cause cancer or damage

the generative function leading to infertility.

•

WARNING

S76W006A

When operating on the vehicle, wear safety gloves,

safety shoes, ear plugs, safety goggles, safety helmet,

working clothes, etc. appropriate for your working envi-

ronment.

Never wear loose ﬁtting clothing or a tie which can be

caught by rotating part. According to the statistics, most

accidents occurred with rotating parts are due to this

inappropriate manner of wearing clothes.

2.2 WORKPLACE

The work should be done in a wide, level and safe

place to prevent slip and fall accident.

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-

er. The bulb can start a ﬁre due to the leaked fuel when

it is broken.

2.2.4 SAFETY EQUIPMENT

Be sure to keep a ﬁrst aid kit and ﬁre extinguisher han-

dy at all times.

2.2.5 KEEPING YOUR WORK AREA CLEAN

Keep the working area clean before and during work. If any

oil or fuel is spilled, it should be cleaned up immediately.

SAFETY FIRST - SAFETY TIPS

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1-4 SUUV-W00 Apr. 2011

SAFETY FIRST

GENERALENGINECVT

TRANSMISSION

CHASSISREAR AXLEBRAKEFRONTAXLESTEERINGHYDRAULICELECTRICINDEX

S76W010A

2.3 SAFETY INSTRUCTIONS WHEN

PREPARING TRACTOR

Stop the engine and remove the key.

Put "No Operation" label on the tractor if necessary.

•

2.4 FIRE

S76W011A

Never smoke or allow ﬂames or sparks in your work

area when maintaining the fuel system.

•

S76W012A

Keep ﬂames or sparks away from the fuel container,

spray paint, etc. and be careful of leaks.

•

S76W013A

Disconnect the negative battery cable.

Always disconnect the battery cable for ﬁre preven-

tion before wiring service.

Be extra cautious of ﬁre when welding.

•

S76W014A

Always keep a ﬁre extinguisher in workplace.•

SAFETY FIRST - SAFETY TIPS

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