CHAPTER 2 MAINTENANCE.docx

CHAPTER 2 MAINTENANCE.docx

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CHAPTER2MAINTENANCE

CHAPTER2MAINTENANCE

2.1PERIODICMAINTENANCE

2.2FUELSYSTEM

2.3TOEALIGNMENT

2.4BRAKINGSYSTEMINSPECTION

2.5SUSPENSIONSPRINGRPELOADADJUSTMENT

2.6WHEELS

2.7TIREPRESSURE

2.8FRAME,NUTS,BOLTS,FASTENERS

2.1PERIODICMAINTENANCE

GENARAL

CAUTION

Markonthefollowingchart

DL：

DuetothenatureoftheadjustmentsmarkedwithaDLonthefollowingchart,itisrecommendedthatservicebeperformedbyanauthorizeddealer.

▲：

Service/Inspectmorefrequentlywhenoperatinginadverseconditions.

PeriodicMaintenanceSchedule

Carefulperiodicmaintenancewillhelpkeepyourvehicleinthesafest,mostreliablecondition.Inspection,adjustmentandlubricationintervalsofimportantcomponentsareexplainedinthefollowingchartonthefollowingpages.

Maintenanceintervalsarebaseduponaverageridingconditionsandanaveragevehiclespeedofapproximately16km/h（10milesperhour）.Vehiclessubjectedtosevereuse,suchasoperationinwetordustyareas,shouldbeinspectedandservicedmorefrequently.

Inspect,clean,lubricate,adjustorreplacepartsasnecessary.

NOTE:

Inspectionmayrevealtheneedforreplacementparts.Alwaysusegenuinepartsavailablefromyourdealer.

Serviceandadjustmentsarecritical.Ifyouarenotfamiliarwithsafeserviceandadjustmentprocedures,haveaqualifieddealerperformtheseoperations.

A=AdjustI=Inspect

C=CleanL=Lubricate

D=DrainR=Replace

T=TightentoCorrectTorque

Item

Hours

When

Remarks

Service（Main）BrakeSystem

/

Pre-ride

I

Auxiliary（Secondary）Brake

/

Pre-ride

I

ParkingBrake

/

Pre-ride

I

Tires

/

Pre-ride

I

Wheels

/

Pre-ride

I

Framenuts,boltsfasteners

/

Pre-ride

I

▲

AirFilter-Pre-Cleaner

/

Daily

IC

Coolant/Level

/

Daily

I

Coolant

150

Annually

R

Coolantstrength

25hrs

3months

IInspectstrengthseasonally

▲

AirBoxSedimentTube

/

Daily

D

HeadlampInspection

/

Daily

C

applydielectricgreasetoconnectorwhenreplaced

Taillampinspection

/

Daily

C

applydielectricgreasetosocketwhenreplaced

▲

AirFilter-MainElement

2

Weekly

IC

Replaceifnecessary

▲

TransmissionOilLevel

10

Monthly

I

changeannually

BatteryTerminals

10

Monthly

IC

Batteryfluidlevel

10

Monthly

I

DL

Brakepadwear

2

Weekly

I

▲

GearcaseOil

10

Monthly

C

150

annually

R

EngineCylinderHeadandCylinderBaseFasteners

25

3months

I

（re-torquerequiredatfirstserviceonly）

▲

GeneralLubrication

allfittings,pivots,cables,etc.

25

3months

L

EngineOil-Level

/

Daily

I

EngineOilChange

30hrs

3months

R

Break-inServiceat1month.Changeoilmoreoftenincoldweatheruse.

▲

OilFilter

50hrs

6months

IC

▲

Enginebreatherhose

100hrs

6months

I

CarburetorFloatBowl

50hrs

6months

Drainbowlperiodicallyandpriortostorage

ThrottleCable

/

Pre-ride

I

DL

ThrottleCable

50hrs

6months

AL（GreaseM）Rifnecessary

Shiftlinkage

50hrs

6months

IARifnecessary

DL

Transmissionbelt

50hrs

6months

I

Rifnecessary

▲

Steering

50hrs

6months

ILTifnecessary

▲

RearAxle（andBearings）

50hrs

6months

IL

▲

FrontSuspension

50hrs

6months

IL

Tifnecessary

▲

RearSuspension

50hrs

6months

I

Tifnecessary

SparkPlug

100hrs

12months

I

Rifnecessary

DL

IgnitionTiming

100hrs

12months

I

Adjustasneeded

DL

FuelSystem

100hrs

12months

Checkforleaksattank,cap,lines,fuelvalve,filter,andcarburetor.Replacelinesevery2years.

DL

FuelFilter

100hrs

12months

R

Radiator

100hrs

12months

IR

CoolingSystemhoses

50hrs

6months

I

Rifnecessary

Sparkarrestor

10hrs

monthly

C

Rifnecessary

DL

Clutches（driveandDriven）

25hrs

3months

IR

Rifnecessary

Enginemounts

25hrs

3months

IT

DL

Valveclearance

100hrs

12months

IA

DL

Shiftselectorbox

（H/L/R/N）

200hrs

24months

Changegreaseeverytwoyears

DL

BrakefluidLevel

/

Pre-ride

I

Brakefluid

200hrs

24months

Changeeverytwoyears

IdleSpeed

/

AsRequired

A

DL

Toeadjustment

/

AsRequired

Periodicinspection,adjustwhenpartsare

replaced

HeadlightAim

/

AsRequired

Adjustifnecessary

▲

DL

Frontdrivechain（andsprockets）intransmission（only4X4model）;

300hrs（fulltimein4X4）,or1000hrs（in2X4alternate4X4）

I,Replaceifnecessary

▲

DL

Balljoint（Aarm-strut）

10hrs

monthly

I,（fordamage,wear,andplay）

R.Replaceifnecessary

▲

drivechain（andsprockets）

（chaindrivesystemonly）

2

Weekly

ICL

Adjustor/andreplaceifnecessary

LUBRICANTANDFLUID

Item

LubeRec

Method

Frequency

1.EngineOil

SAE15W/40SE

Addtoproper

levelondipstick

Checkleveldaily

2.BrakeFluid

DOT3Only

Maintainlevel

Betweenfilllines.See“7.CONTROL”

Asrequire;change

everytwoyearsor200hours

3.TransmissionOil

SEA80W/90GL5

Addtoproper

levelondipstick

Changeannuallyorat

100hours

4.RearGearcaseoil

SEA80W/90GL5

Addtoproper

level

Changeannuallyor

at100hours

5.FrontGearcaseoil（4X4）

SEA80W/90GL5

Addtoproper

level

Changeannuallyor

at100hours

▲

6.FrontA-arm

pivotShaft

Grease

Locatefittingonpivotshaftandgreasewithgreasegun

Every3monthsor50hours

（ExceptMaintenance-FreeA-armpivot）

▲

7.Steering

PostBushings

Grease

Locatefittingon

pivotshaftand

greasewithgreasegun

Every3monthsor50hours

▲

8.FrontWheel

bearings

Grease

（hightemperatureresist）

Inspectandreplacebearingsifnecessary

Semi-annually

9.Tierods

Grease

Locatefittingsandgrease

Semi-annually

10.Shift

Linkages

Grease

Locatefittingsandgrease

Semi-annually

▲

11.Balljoints

Inspect

Inspectandreplaceitifnecessary

Semi-annually

▲

12.RearAxle

Bearing

Grease

Locatefittingsandgrease

Every3monthsor50hours

▲

13.SwingArm

Bearing

Grease

Locatefittingsandgrease

Monthlyor20hours

▲

14.Throttle

Cable

GreaseM

Grease,inspectandreplaceitifnecessary

Monthlyor20hours

15.RearpropshaftU-joint

Grease

Locatefittingsandgrease

Every3monthsor50hours

16.Rearpropshaftyoke

Grease

Locatefittingsandgrease

Every3monthsor50hours

17.FrontpropshaftU-joint（4WD）

Grease

Locatefittingsandgrease

Every3monthsor50hours

18.Frontpropshaftyoke（4WD）

Grease

Locatefittingsandgrease

Every3monthsor50hours

19.InnerandouterCV-Joints（4WD）

GreaseM

Grease,inspectandreplaceitifnecessary

Every3monthsor50hours

▲

20.Drivechain（andsprockets）

（chaindrivesystemonly）

Lubricate

ICL

Adjustor/andreplaceifnecessary

Weekly

21.A-armpivotshaft

Grease

Locatefittingsandgrease

Every3monthsor50hours

LubricationRecommendations

NOTE:

1.Moreoftenundersevereuse,suchaswetordustyconditions.

2.Grease:

Lightweightlithium-soapgrease.

3.GreaseM：

Molybdenumdisulfide（MoS2）grease（waterresistant）.

4.*Whensuspensionactionbecomesstifforafterwashing.

5.Hoursarebasedon10mph（16Km/h）average.

2.2FUELSYSTEM

WARNING

Gasolineisextremelyflammableandexplosiveundercertainconditions.

Alwaysstoptheengineandrefueloutdoorsorinawellventilatedarea.

Donotsmokeorallowopenflamesorsparksinorneartheareawhererefuelingisperformedorwheregasolineisstored.

Donotoverfillthetank.Donotfillthetankneck.

Ifyougetgasolineinyoureyesorifyouswallowgasoline,seeyourdoctorimmediately.

Ifyouspillgasolineonyourskinorclothing,immediatelywashitoffwithsoapandwaterandchangeclothing.

Neverstarttheengineorletitruninanenclosedarea.Gasolinepoweredengineexhaustfumesarepoisonousandcancauselossofconsciousnessanddeathinashorttime.

Neverdrainthefloatbowlwhentheengineishot.Severeburnsmayresult.

ATV260/300

ATV50/80/100/150

FUELLINES

Checkfuellinesforsignsofwear,deterioration,damageorleakage.Replaceifnecessary.

Besurefuellinesareroutedproperlyandsecuredwithcableties.

CAUTION:

Makesurelinesarenotkinkedorpinched.

Replaceallfuellineseverytwoyears.

VENTLINES

1.Checkfueltank,oiltank,carburetor,battery,andtransmissionventlinesforsignsofwear,deterioration,damageorleakage.Replaceeverytwoyears.

2.Besureventlinesanddrainlinesareroutedproperlytowardthegroundandsecuredwithcableties.CAUTION:

Makesurelinesarenotkinkedorpinched

FUELFILTER

ThefuelfiltershouldbereplacedinaccordancewiththePeriodicMaintenanceChartorwheneversedimentisvisibleinthefilter.

1.Shutofffuelsupplyatfuelvalve.

2.Removelineclampsatbothendsofthefilter.

3.Removefuellinesfromfilter.

4.Installnewfilterandclampsontofuellineswitharrowpointedindirectionoffuelflow.

5.Installclampsonfuelline.

6.TurnfuelvalveON.

7.Startengineandinspectforleaks.

8.Reinstallfueltank.

WARNING

Alwayspayattentiontothefittingsoftheplasticgastankduringfuellinesservice.Don’tpullthelinefromthetankdirectlyforremoval.Inspectfittingsandtankbodyforlooseness,nicks,andscratches.Replacegastankifnecessary.

2.3TOEALIGNMENT

METHOD:

STRAIGHTEDGEORSTRING

Besuretokeephandlebarscentered

NOTE:

StringshouldjusttouchsidesurfaceofreartireoneachsideoftheATV.

Measurefromstringtorimatfrontandrearofrim.

Rearrimmeasurement（A）shouldbe1/16"to1/8"（1.5to3mm）morethanfrontrimmeasurement（B）.

NOTE:

Thesteeringpostarm（frog）canbeusedasanindicatorofwhetherthehandl