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PERIODIC MAINTENANCE 2-1
2
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-2
Torque and Locking Agent...................................................................................................... 2-3
Specifications ......................................................................................................................... 2-8
Special Tools and Sealant ...................................................................................................... 2-9
Periodic Maintenance Procedures .......................................................................................... 2-10
Fuel System......................................................................................................................... 2-10
Throttle Control S ystem Inspection................................................................................... 2-10
Air Filter Drain Caps Inspection and Cleaning.................................................................. 2-10
Air Filter Inspection and Cleaning..................................................................................... 2-11
Fuel Vent Check Valve Inspection .................................................................................... 2-11
Fuel Pump Screen Cleaning............................................................................................. 2-12
Throttle Shaft S pring Inspection........................................................................................ 2-12
Engine Lubrication System.................................................................................................. 2-12
Engine Oil Change............................................................................................................ 2-12
Oil Filter R eplace .............................................................................................................. 2-14
Engine Top End ................................................................................................................... 2-15
Air Suction Valve Inspection ............................................................................................. 2-15
Valve Clearance Inspection .............................................................................................. 2-15
Engine Mounting Bolts Inspection and Tightness ............................................................. 2-19
Engine Bottom End.............................................................................................................. 2-19
Coupling Damper Inspection............................................................................................. 2-19
Cooling and Bilge Systems.................................................................................................. 2-19
Cooling System Flushing .................................................................................................. 2-19
Bilge System Flushing ...................................................................................................... 2-21
Pump and Impeller............................................................................................................... 2-22
Impeller Inspection............................................................................................................ 2-22
Steering ............................................................................................................................... 2-22
Steering Cable/Shift Cable Inspection .............................................................................. 2-22
Handlebar Pivot Lubrication.............................................................................................. 2-22
Hull/Engine Hood.................................................................................................................2-23
Drain Plug Inspection........................................................................................................ 2-23
Electrical System ................................................................................................................. 2-23
Battery Charging Condition Inspection ............................................................................. 2-23
Battery Terminals Inspection............................................................................................. 2-23
Spark Plug Cleaning and Inspection................................................................................. 2-24
Lubrication ........................................................................................................................... 2-24
All Hoses, Hose Clamps, Nuts, Bolts and Fasteners Check ............................................... 2-27
Nuts, Bolts, and Fasteners Tightness Inspection.............................................................. 2-27
Hose and Hose Connect Inspection ................................................................................. 2-27
Rubber Strap Inspection ................................................................................................... 2-29