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PERIODIC MAINTENANCE 2-1
2
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-3
Torque and Locking Agent................. 2-5
Specifications .................................... 2-11
Special Tools ..................................... 2-13
Periodic Maintenance Procedures..... 2-14
Fuel System.................................... 2-14
Throttle Lever Free P lay
Inspection.................................. 2-14
Throttle Lever Free P lay
Adjustment ................................ 2-14
Choke Lever Free Play
Inspection.................................. 2-14
Choke Lever Free Play
Adjustment ................................ 2-15
Idle Speed Inspection .................. 2-15
Idle Speed Adjustment................. 2-16
Fuel System Cleanliness
Inspection.................................. 2-16
Air Cleaner Element Cleaning and
Inspection.................................. 2-17
Air Cleaner Draining..................... 2-17
Fuel Hose and Connection
Inspection.................................. 2-18
Fuel Hose R eplacement .............. 2-18
Cooling System............................... 2-19
Radiator Cleaning ........................ 2-19
Radiator Hose and Connection
Inspection.................................. 2-20
Coolant Change........................... 2-20
Engine Top E nd .............................. 2-23
Valve Clearance Inspection ......... 2-23
Valve Clearance Adjustment........ 2-24
Spark Arrester Cleaning............... 2-24
Converter System ........................... 2-25
Drive Belt Inspection .................... 2-25
Drive Belt Deflection Inspection... 2-25
Drive Belt Deflection Adjustment . 2-26
Actuator Lever (Engine Brake
Control Lever) Assembly
Inspection.................................. 2-27
Engine Lubrication System............. 2-27
Engine Oil Change....................... 2-27
Oil Filter Replacement ................. 2-28
Wheels/Tires................................... 2-28
Tire Inspection ............................. 2-28
Final Drive....................................... 2-29
Variable Differential Control Lever
Play Inspection.......................... 2-29
Variable Differential Control Lever
Play Adjustment ........................ 2-29
Front Final Gear Case Oil
Change...................................... 2-30
Rear Final Gear Case Oil Change 2-31
Universal Joint Lubrication........... 2-32
Brakes............................................. 2-32
Front Brake Pad Wear Inspection 2-32
Front Brake Hoses and
Connections Inspection............. 2-32
Front Brake Hose Replacement... 2-33
Brake Fluid Level Inspection........ 2-33
Brake Fluid Change ..................... 2-34
Front Brake Master Cylinder
Piston Assembly and Dust Seal
Replacement ............................. 2-34
Front Brake Caliper Piston Seal
and Dust Seal R eplacement ..... 2-34
Rear Brake Plates Replacement.. 2-35
Rear Brake Lever Free Play
Inspection.................................. 2-35
Brake Pedal Free Play Inspection 2-35
Rear Brake Lever and Pedal Free
Play Adjustment ........................ 2-35
Steering .......................................... 2-36
Steering Inspection ...................... 2-36
Electrical System ............................ 2-36
Spark Plug Cleaning/Inspection... 2-36
Spark Plug Gap Inspection .......... 2-36
Brake Light Switch Inspection...... 2-37
Brake Light Timing Adjustment .... 2-37
Drive Belt Failure Detection
System Inspection..................... 2-37
Joint Boots Inspection..................... 2-39
Front Axle/Knuckle Joint Boot
Inspection.................................. 2-39
Front Propeller Shaft Boot
Inspection.................................. 2-39
Tie-rod End Boot Inspection ........ 2-39
Rear Propeller Shaft Joint Boot
Inspection.................................. 2-39
Rear Axle/Stabilizer Joint Boot
Inspection.................................. 2-39
General Lubrication ........................ 2-40