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5.1.15 Lubricate caster wheel hubs:
Service Interval: Once Yearly
a) Stop engine, wait for all moving par ts to stop, and r em o ve k ey.
b) Remove caster wheel from cast er forks.
c) Remove seal guards from the wheel hub.
d) Remove one of the spacer nut s from
the axle assembly in the caster wheel.
Note that thread locking adhesive has
been applied to lock t he spacer nuts to
the axle. Remove the axle (with the
other spacer nut still assembled to it)
fr om the wheel assembly.
e) Pry out seals, and inspect bearings f or
wear or damage and replace if
necessary.
f) Pack the bear ings with NGLI g r ade #1 m ulti-purpose g r ease.
g) Insert ( 1) bearing, ( 1) new seal into the wheel.
NOTE: Seals (Exmark PN 103-0063) must be r eplaced.
h) If t he axle assembly has had both spacer nut s r emoved (or broken loose) ,
apply a thread locking adhesive to (1) spacer nut and t hr ead onto the axle
with the wrench flats facing outward. Do not t hr ead spacer nut all of t he way
onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer
surf ace of the spacer nut to the end of t he axle inside the nut .
i) Insert t he assembled nut and axle into the wheel on the side of t he wheel
with the new seal and bearing.
j) With the open end of t he wheel f acing up, fill the area inside the wheel
around the axle f ull of NGLI grade #1 mult i- pur pose grease.
k) Insert the second bearing and new seal into the wheel.
l) Apply a thread locking adhesive to the 2nd spacer nut and t hr ead onto the axle
with the wrench flats f acing outward.
m) Torque the nut to 75- 80 in- lbs. ( 8-9 N-m), loosen, then re-tor que to 20-25
in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut .
n) Re-install the seal guards over the wheel hub and insert wheel into caster
for k. Re-inst all cast er bolt and tig ht en nut fully.
IMPORTANT: To prevent seal and bear ing damage, check the bear ing
adjustment often. Spin the caster tire. The tire should not spin fr eely
(more t han 1 or 2 r evolutions) or have any side play. If the wheel spins
fr eely, adj ust torque on spacer nut until there is a slig ht amount of drag.
Re-apply threadlock ing adhesive.
5.1.16 Lubricate seat switch actuat or :
Service Interval: 160 hrs.
a) Stop engine, wait for all moving par ts to stop, and r em o ve k ey.
b) Unhook seat lat c h and t ilt seat up.
c) Lubricate switch actuator r od with spray type lubricant or light oil.
5.1.17 Lubricate brake handle pivot:
Service Interval: 160 hrs.
a) Stop engine, wait for all moving par ts to stop, and r em o ve k ey.
FIGURE 8
CASTER WHEEL ASSEMBLY