Maintenance
| Figure 12 |
1. Seal guard | 2. Spacer nut with wrench |
| flats |
2.Remove caster wheel from caster forks.
3.Remove seal guards from the wheel hub.
4.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.
5.Pry out seals, and inspect bearings for wear or damage and replace if necessary.
6.Pack the bearings with a NGLI grade #1
7.Insert one bearing, one new seal into the wheel.
Note: Seals (Exmark PN
8.If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one 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 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.
9.Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.
10.With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NGLI grade #1
11.Insert the second bearing and new seal into the wheel.
12.Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.
13.Torque the nut to
14.Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall 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. Reapply thread locking adhesive.
Remove Engine Shrouds and Clean Cooling Fins
Service Interval: Every 80 hours
1.Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.
2.Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling.
3.Make sure cooling shrouds are properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating.
Check Spark Plugs
Service Interval: Every 160 hours
Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owners Manual.
Change Fuel Filter
Service Interval: As required
A fuel filter is installed in the fuel line between the fuel tank and the engine. Replace when necessary.
Replacement Filters
Kawasaki | Kawasaki P/N |
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