2004-2010 Kubota RTV900 UTV Service & Repair Manual

WORKSHOP MANUAL UTILITY VEHICLE RTV900 KiSC issued 03, 2008 A

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of RTV900. It is divided into three parts, "General", "Mechanism" and "Servicing". ■ General Information on the product identification, the general precautions, maintenance check list, check and maintenance and special tools are described. ■ Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Refer to Diesel Engine Workshop Manual (Code No. 9Y021-01872) for the one which has not been described to this workshop manual. ■ Servicing Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits. All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. Due to covering many models of this manual, information or picture being used have not been specified as one model. January 2004 © KUBOTA Corporation 2004 KiSC issued 03, 2008 A

1 RTV900, WSM SAFETY INSTRUCTIONS BEFORE SERVICING AND REPAIRING • Read all instructions and safety instructions in this manual and on your machine safety decals. • Clean the work area and machine. • Park the machine on a firm and level ground, and set the parking brake. • Lower the implement to the ground. • Stop the engine, and remove the key. • Disconnect the battery negative cable. • Hang a “DO NOT OPERATE” tag in operator station. SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit. DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. ■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. ■ NOTE : Gives helpful information. KiSC issued 03, 2008 A

2 RTV900, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Do not alter or remove any part of machine safety system. • Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions. • Never start the engine while standing on ground. Start the engine only from operator’s seat. SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job. • Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended. • When servicing is performed together by two or more persons, take care to perform all work safely. • Do not work under the machine that is supported solely by a jack. Always support the machine by safety stands. • Do not touch the rotating or hot parts while the engine is running. • Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. • Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure. • Do not open high-pressure fuel system. High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair fuel lines, sensors, or any other components between the high-pressure fuel pump and injectors on engines with high pressure common rail fuel system. • High voltage exceeding 100 V is generated in the ECU, and is applied to the injector. Pay sufficient caution to electric shock when performing work activities. KiSC issued 03, 2008 A

3 RTV900, WSM SAFETY INSTRUCTIONS AVOID FIRES • Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. • To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. • Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery. • Make sure that no fuel has been spilled on the engine. VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. PREVENT ACID BURNS • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately. DISPOSE OF FLUIDS PROPERLY • Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste. KiSC issued 03, 2008 A

4 RTV900, WSM SAFETY INSTRUCTIONS PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher handy at all times. • Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. KiSC issued 03, 2008 A

5 RTV900, WSM SAFETY INSTRUCTIONS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal parts number is listed in the parts list. SAFETY DECALS KiSC issued 03, 2008 A

6 RTV900, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A

2004-2010 Kubota RTV900 UTV Service & Repair Manual

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