ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
For further engine information, see Engine Shop
Rebuild and Service Parts Manual.
Fill Cold Engine
To This Point
POWERTRAIN MAINTENANCE
Access the powertrain by raising or removing seat.
Some service procedures may require the vehicle be
lifted. Refer to LIFTING THE VEHICLE in section ‘B’ for
proper lifting procedure and safety information.
Add Oil
Checking the Oil Level
Maximum Oil Level
For Hot Engine
Do Not Overfill
Safe
Operating Range
Hot Engine
Fig. 2 Check Oil Level on Dipstick
Do not overfill engine. Too much oil may cause smoking
or allow oil to enter the air filter enclosure.
The oil should be checked with the engine warm. The
vehicle should be on a level surface with the parking
(PARK) brake engaged. Allow adequate time for oil to
drain into the crankcase before checking.
Remove the dipstick and wipe off the entire area with a
lint free cloth (Ref. Fig. 1).
The engine can be operated safely as long as oil is
within the safe operating range as indicated on the dip
stick. Do not operate vehicle if oil level is below the
safe area indicated on the dipstick.
Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot,
Do not overfill (Ref. Fig. 2). Check that the oil cap is
firmly in place.
NOTICE
When adding oil between oil changes, do not mix brands and
viscosity grades of oil.
Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will
result in oil becoming contaminated and/or oil being discharged into the engine compartment.
Changing the Oil
Tool List
Qty.
Socket, 19 mm ............................................................ 1
Ratchet ........................................................................ 1
Extension, 8" ............................................................... 1
Oil Drain Pan ............................................................... 1
Oil Filter Wrench.......................................................... 1
For maximum performance and longevity, the engine oil
should be replaced after the first 8 hours of operation.
After the initial oil change, it should be changed every
125 hours of operation or semi-annually, whichever
comes first.
Fig. 1 Clean Entire Dipstick
Insert the dipstick fully into the dipstick opening and
remove. Examine the level of the oil on the dipstick.
The selection of oil is dependent upon the service that
the vehicle will perform. Most vehicles require 10W-30
oil, whereas vehicles used at capacity or near capacity
load applications will utilize 10W-40 oil after a break-in
period of 8 hours (Ref. Fig. 3).
Repair and Service Manual
Page G-1
ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
B
HEAVY DUTY WORK
10W-40
10W-30
Be careful of hot oil when drained. It may be
hot enough to burn you severely
LIGHT DUTY WORK
Place the oil drain pan under the oil drain plug (1) found
at the rear of the engine base. Remove the drain plug
(1), allow the oil to drain into the drain pan.
10W-30
F
0
-20
C 0 -30
0
-20
20
40
60
80
-10
0
10
20
(AIR TEMPERATURE)
100
30
40
2
Fig. 3 Oil Viscosity Chart
1
NOTICE
If vehicle is to be stored over winter months, it can be stored
with old oil left in engine. The oil should be changed as part of
spring maintenance. This will remove any moisture that has
accumulated during storage.
Be aware that engine fluids may be hot and
contact to the skin may cause severe burns.
Wear rubber gloves to protect skin from exposure to the old oil and degreaser.
The oil should be changed with engine warm. Park vehicle on a
level surface, engage parking brake and remove key. Place a
drain pan under engine. Wipe top of the engine clean with a cloth
(Ref. Fig. 4). Remove the oil fill cap.
Fig. 5 Oil Drain Plug
Before installing the drain plug clean the area around
the drain plug mount with a lint free cloth and inspect the
drain plug (1) for damage; replace if necessary (Ref. Fig.
5). If the ’O’ ring (2) on the drain plug is damaged
replace it with a new one and tighten to the specified
torque.
ITEM
TORQUE SPECIFICATION
1
61 in. lbs (7 Nm)
At the first oil change, small metal chips and lint may be
found. This is normal, resulting from the break-in period.
Inspect the filter at every oil change. The presence of
large metal chips could indicate possible damage to the
engine.
Oil Fill Cap
3
4
Fig. 6 Remove Oil Filter
Fig. 4 Cleaning Top of Engine
Page G-2
Clean the area around filter. Place the oil drain pan
under the filter area. Using a filter wrench, strap wrench
or other suitable filter wrench (3), remove the filter (4)
Repair and Service Manual
ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
from the engine and allow the oil to drain into the oil
drain pan (Ref. Fig. 5). The ‘O’ ring (5) may remain on
engine (6) or filter (7) (Ref. Fig. 6).
Inspect the filter to make sure the ‘O’ ring is not left on
the engine surface (6), if the ’O’ ring has remained on
the engine surface remove it and discard with the filter.
NOTICE
Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will
result in oil being discharged into the engine compartment.
As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume when warm. The full ‘F’ mark on the dipstick is
calibrated for an engine at operating temperature. When
the engine is cold, the oil will be below the full mark. The
engine can be operated safely as long as the oil is within
the safe operating range as indicated on the dipstick.
DO NOT operate vehicle if oil level is below the safe
area indicated on the dipstick.
5
7
6
Fig. 7 Inspect Oil Filter
Inspect the new oil filter for any defects, apply engine oil
to the ’O’ ring seal and install the new oil filter onto the
engine until the seal contacts mounting surface of the
engine. Then turn the filter 2/3 to 3/4 rotation by
HAND(S). Pour in the specified type and amount of oil.
AIR FILTER INSPECTION/REPLACEMENT
Oil capacity is 1.4 quarts (1.3 liters). Add slightly less
than 1.4 quarts (1.3 liters) to allow for possible residual
oil left in engine (Ref. Fig. 8). The oil must be high quality oil that meets or exceeds API SF, SG, CC standards
(Ref. Fig. 3). Check oil level on dipstick. Oil should be
slightly below ‘H’ to allow for expansion. If necessary,
continue to add oil slowly and allow time for oil to flow
down into engine. Check oil level on dipstick. Do NOT
overfill.
Fig. 9 Air Cleaner
DO NOT overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.
NOTICE
The air cleaner unit on the vehicle is a dry unit. Do not use oil
on the filter element or any part of the unit.
Fig. 8 Add Engine Oil
The air cleaner may be accessed by raising the seat
(Ref. Fig. 9). Unsnap the clip and turn the cover in a
counter clockwise direction to remove cover. Inspect
and replace the air filter element in accordance with the
Periodic Service Schedule (Ref Section A). Clean inside
of cover and canister (Ref. Fig. 10). Install the element
into the housing followed by the cover. Turn the cover in
a clockwise direction to make sure that it is secure and
latch the clip to keep it in place.
Repair and Service Manual
Page G-3
B
B
ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
B
STARTER/GENERATOR BELT TENSION
Tool List
Qty.
Belt Tension Gauge .....................................................1
Wrench, 13 mm............................................................1
Wrench, 14 mm............................................................2
Wrench, 15 mm............................................................1
Ratchet ........................................................................1
Socket, 13 mm"............................................................1
Socket, 15 mm .............................................................1
The starter/generator belt tension should be checked
after the first 15 - 20 hours and set to 75 - 80 lbs. (34 36 kg).
NOTICE
A loose belt can cause audible vibration and squeal.
Tighten a new starter/generator belt to 90 - 110 lbs. (41 50 kg) tension when a gauge is applied half way
between the two pulleys (Ref. Fig. 11).
Fig. 10 Air Filter Assembly
Cleaning the Air Filter Element
Do NOT use compressed air to clean the air filter. Doing
so will damage the filter and will damage the engine.
If the element is in acceptable condition, loose dirt may
be removed by tapping the filter lightly. Do NOT use oil
on the filter element or any part of the unit. Install the
element in the same way it was removed, being sure
that the cover clip is fastened securely.
Fig. 11 Checking Belt Tension with Gauge
Although not as accurate, a new belt may be depressed
with a finger. A maximum deflection of 3/8" (10 mm) is
acceptable (Ref. Fig. 12).
3/8" (1 cm) Maximum
Deflection (New Belt)
1/2" (1.3 cm) Maximum
Deflection (Existing Belt)
Fig. 12 Checking Belt Tension with Finger
Page G-4
Repair and Service Manual
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