Service Interval Once Yearly, Caster Wheel Assembly

c)Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on.

5.1.16Lubricate caster wheel hubs:

Service Interval: Once Yearly

a)Stop engine, wait for all moving parts to stop, and remove key.

b)Remove caster wheel from caster forks.

c)Remove seal guards from the wheel hub.

d)Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to

lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

FIGURE 8

CASTER WHEEL ASSEMBLY

e)Pry out seals, and inspect bearings for wear or damage and replace if necessary.

f)Pack the bearings with a NGLI grade #1 multi-purpose grease.

g)Insert (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

h)If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to (1) spacer nut and thread onto the axle with the wrench flats facing outward. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.

i)Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

h)With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease.

i)Insert the second bearing and new seal into the wheel.

j)Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.

k)Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to 20-25 in- lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.

l)Re-install the seal guards over the wheel hub and insert wheel into caster fork. Re-install caster bolt and tighten nut fully.

IMPORTANT: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust torque on spacer nut until there is a slight amount of drag. Re-apply threadlocking adhesive.

5.1.17Check spark plugs. Service Interval: 160 hrs.

a)Remove spark plugs, check condition and adjust plug gap or replace with new plugs. See Engine Owner's Manual.

5.1.18Remove engine shrouds and clean cooling fins. Service Interval: 80 hrs.

a)Stop engine, wait for all moving parts to stop, and remove key.

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