ATVSV2.PDF

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SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
2
TABLE OF
CONTENTS
Valve/Tappet Clearance
(Feeler Gauge Procedure) ..........2-12
Valve/Tappet Clearance
(Valve Adjuster Procedure) .........2-13
Engine/Transmission Oil - Filter - Strainer
Engine/Transmission Oil - Filter - Strainer
Adjusting Clutch
Adjusting Reverse Shift Lever
(Manual Transmission) ............2-25
Adjusting Shift Lever
(Automatic Transmission) ..........2-26
Hydraulic Foot Brake System
Checking/Replacing V-Belt
(Automatic Transmission) ..........2-33
2-1
719578267.007.png
Periodic Maintenance
Chart
A = Adjust
I = Inspect
C = Clean
L = Lubricate
D = Drain
R = Replace
Item
Initial Service
After Break-In
(First Mo or
200 Mi)
Every
Day
Every Month or
Every 100 Miles
Every 3
Months or
Every 300 Miles
Every 6
Months or
Every 500 Miles
Every Year or
Every 1500
Miles
As Needed
Battery
I
I
C
Fuses
I
R
Air Filter/Drain Tube
I
I
C*
R
Valve/Tappet Clearance
I
I
A
Engine Compression
I
Spark Plug
I
R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester
C
R
Gas/Vent Hoses
I
C
Gas Tank Valve
I
C
Throttle Cable
I
I
C, L
A, R
Carb Float Chamber
D*
Engine RPM (Idle)
I
I
A
Engine-Transmission Oil Level
I
A
Engine-Transmission Oil/Filter
R
I
R*
R
Oil Strainer
I
I
C
Front Differential/Rear Drive
Lubricant
I
I
l
l
R
Clutch
I
l
A
Tires
I
R
Steering Components
I
I
I
R
V-Belt
I
l
R
Suspension (Ball joint boots,
drive axle boots front and
rear, tie rods, differential and
rear drive bellows)
l*
R
Nuts/Cap Screws/Screws
I
I
I
A
Ignition Timing
I
Headlight/Taillight-Brakelight
I
I
R
Switches
I
R
Reverse Shift Lever
I
A, L
Choke Cable
I
C,L
R
Recoil Starter
I
C/R
Handlebar Grips
I
R
Handlebars
I
R
Gauges/Indicators
I
R
Frame/Welds/Racks
I
l
Electrical Connections
l
C
Complete Brake System
(Hydraulic & Mechanical)
I
I
C
L, R
Brake Pads
I
I*
R
Brake Fluid
I
I
R (2 Yrs)
Brake Hoses
I
I
R (4 Yrs)
Coolant/Cooling System
I
I
R (2 Yrs)
Coolant/Cooling System
I
I
R (2 Yrs)
* Service/Inspect more frequently when operating in adverse conditions.
2-2
719578267.008.png
Fig. 2-2
Lubrication Points
1.28
1.24
It is advisable to lubricate certain components
periodically to ensure free movement. Apply light oil to
the components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Mechanical Brake Cable Ends
D. Choke Cable Upper End
E. Reverse Lever Cable End
F. Idle RPM Screw (Carburetor)
1.20
1.16
1.12
1.08 0246802468
Charging Time (Hour)
ChargTim
Fig. 2-3
2
1.30
1.29
1.28
1.27
1.26
1.25
1.24
1.23
1.22
1.21
Battery
Normal
Charge
Fig. 2-1
Charge or Replace
°C
0
5 10152025303540
104
°F 32
41
50
59
68
77
86
95
Temperature
Charge
To remove and charge the battery, use the following
procedure.
AF879D
The level of the battery fluid must be kept between the
upper and lower level lines at all times. If the level drops
below the lower level line, add only distilled water
until it reaches upper level line.
! WARNING
Anytime service is performed on a battery, the
following must be observed: keep sparks, open
flame, cigarettes, or any other flame away. Always
wear safety glasses. Protect skin and clothing
when handling a battery. When servicing battery
in enclosed space, keep the area well-ventilated.
Make sure battery venting is not obstructed.
! WARNING
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
handling a battery.
1. Remove the battery hold-down bracket.
2. Remove the negative battery cable; then remove the
positive cable and the battery vent tube. Remove the
battery from the ATV. Care should be taken not to
damage the vent tube.
If the battery is discharged, remove the battery from the
ATV and charge the battery at the standard charging rate
of 1.4A x 10 hr.
! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.
2-3
719578267.009.png 719578267.010.png
! CAUTION
Fuses
Do not charge the battery while it is in the ATV
with the battery terminals connected.
3. Remove the vent plugs; then (if necessary) fill the
battery with distilled water to the upper level
indicated on the battery.
On the 250/300 cc, the fuses are located in the center of
the front fender beneath a snap-on cover.
4. Trickle charge the battery at 1.4 amps for 10 hours.
Fig. 2-5
! CAUTION
Never exceed the standard charging rate.
5. After charging, check fluid level and fill with
distilled water as necessary; then install vent
plugs.
! CAUTION
Before installing the battery, make sure the
ignition switch is in the OFF position.
AR662D
On the 400/500 cc, the main fuse is located near the
right side of the air silencer. A spare main fuse is stored
under the starter motor relay.
6. Place the battery into position in the ATV and
secure with the hold-down bracket.
On the 400/500 cc, the remaining fuses are located near
the right side of the air-intake snorkel.
7. Attach the vent tube and check the vent tube to
make sure it is not crimped or obstructed in any way
and that it is properly routed through and secured to
the frame.
NOTE: To remove the fuse, compress the locking
tabs on either side of the fuse case and lift out.
If there is any type of electrical system failure, always
check the fuses first.
8. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative cable
to the negative terminal (-). Connect the negative
cable last.
Fig. 2-6
Fig. 2-4
AR655D
AF733D
! CAUTION
! CAUTION
Always replace a blown fuse with a fuse of the
same type and rating.
Connecting cables in reverse (positive to
negative and negative to positive) can cause
serious damage to the electrical system.
2-4
719578267.001.png 719578267.002.png
Fig. 2-9
Air Cleaner
(250/300 cc)
The two-part air filter inside the air cleaner must be kept
clean to provide good engine power and gas mileage. If
the ATV is used under normal conditions, service the
filter at the intervals specified. If operated in dusty, wet,
or muddy conditions, inspect and service the filter more
frequently.
CLEANING AND INSPECTING FILTER
CH046D
4. Remove the foam wrap from the filter.
2
! CAUTION
Fig. 2-10
Failure to inspect the air filter frequently if the
ATV is used in dusty, wet, or muddy conditions
can damage the ATV engine.
1. Remove the seat.
2. Remove the two machine screws securing the air
cleaner housing cover.
Fig. 2-7
AL642D
5. Wash the polyester filter and the foam wrap with
warm soapy water and rinse.
6. Allow the foam wrap to air dry thoroughly.
CH044D
NOTE: Either allow the polyester filter to air dry or
blow dry using low-pressure compressed air. Direct
the compressed air through the filter from the
opposite direction as normal operation air flow.
3. Pull the retainer out and remove the filter with foam
wrap.
! CAUTION
Fig. 2-8
Do not put oil on either the filter or the foam
wrap.
7. Place the foam wrap around the air filter; then
install the filter with wrap into the air cleaner
making sure it is properly in position and properly
seated and secure with the retainer.
CH045D
2-5
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