- 24 -
c) Lubricate 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 t hr ead plug back in. Place cap back on.
5.1.12 Lubricate rear cast er wheel hub:
Service Interval: Once Yearly
a) Stop engine, wait for all moving par ts to
stop, and remove 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 thr ead locking adhesive has been
applied to lock t he spacer nuts to the
axle. Remove the axle (with the other
spacer nut still assem bled to it) from 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 a 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 multi-purpose gr ease.
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 bearing
adjustment often. Spin t he caster tire. The tire should not spin freely
(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 dr ag.
Re-apply threadlock ing adhesive.
5.1.13 Lubricate seat switch actuat or :
Service Interval: 160 hrs.
a) Stop engine, wait for all moving par t s t o stop, and remove k e y.
b) Tilt seat up.
c) Lubricate switch actuator rod with spray type lubricant or light oil.
FIGURE 5
CASTER WHEEL ASSEMBLY