3
3 - 1
CHK
ADJ
PERIODIC MAINTENANCE/LUBRICATION
INTRODUCTION
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to machines already in service as well as to new machines that are being prepared for sale.
All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE AND LUBRICATION CHART
NO.
ITEM
CHECK OR MAINTENANCE
JOB
INITIAL
EVERY
Whichev-
er comes
first
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
1
*
Fuel line
Check fuel hoses for cracks or other damage, and
replace if necessary.
√
√
√
2
Spark plug
Check condition and clean, regap, or replace if
necessary.
√
√
√
√
√
3
*
Valves
Check valve clearance and adjust if necessary.
√
√
√
√
4
*
Carburetor
Check choke operation and correct if necessary.
Check engine idling speed and adjust if neces-
sary.
√
√
√
√
5
*
Crankcase breather
system
Check breather hose for cracks or other damage,
and replace if necessary.
√
√
√
6
*
Exhaust system
Check for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.
√
√
√
7
Spark arrester
Clean.
√
√
√
NO.
ITEM
CHECK OR MAINTENANCE
JOB
INITIAL
EVERY
Whichev-
er comes
first
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
1
Air filter element
Clean and replace if necessary.
Every 20–40 hours (more often in wet or
dusty areas)
3
*
Front brake
Check operation and correct if necessary.
Check brake lever free play and adjust if neces-
sary.
Replace brake shoes.
Whenever worn to the limit
6
*
Wheels
Check runout and for damage, and replace if nec-
essary.
7
8
*
Tires
Check tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.
4
*
Rear
brake
Check operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.
Replace brake pads.
Whenever worn to the limit
5
*
Brake hoses
Check for cracks or other damage, and replace if
necessary.
Replace.
Replace.
Every 4
years
2
*
Clutch
Check operation.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Fuel filter
Every 600 hours of operation
