B
2
Repair Manual
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
10002660
Fig. 4 Initial Service Chart
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service, pro-
vided it receives regular maintenance (See PERIODIC
SERVICE SCHEDULE on page 133).
Verify appropriate lubrication locations (See Checking the
NOTICE: To prolong vehicle life, some maintenance
items must be serviced more frequently on vehicles
used under severe driving conditions such as
extreme temperatures, extreme dust/debris condi-
tions, or frequent use with maximum load.
POWERTRAIN MAINTENANCE
The powertrain is most easily accessed from the under-
side of the vehicle (See LIFTING THE VEHICLE on
page 8). Remove the cowl for full access to the front pow-
ertrain (See Cowl Replacement on page 25). Remove the
rear seat for full access to the rear powertrain (See Rear
Seat Removal and Installation on page 75).
Use insulated wrenches to prevent
the possibility of a dropped wrench
causing a short-circuit in a battery,
which can cause an explosion and severe personal
injury or death.
To prevent accidental starting, disconnect the main
negative battery cable before servicing.
BRAKES
This vehicle is equipped with four wheel hydraulic disc
brakes. Check the fluid level at intervals specified (See
PERIODIC SERVICE SCHEDULE on page 133). If fluid
leaks are noticed or the brake pedal seems soft, check
the fluid level immediately. If the brake pedal is soft, the
brake system should be bled to remove air from the brake
lines (See Bleeding on page 38).
The parking brake is an electric motor brake and is
engaged any time that the vehicle comes to a complete
stop. The parking brake is released when the vehicle is in
F (forward) or R (reverse) and the accelerator pedal is
pressed.
After the vehicle has been put into service, it is recom-
mended that the brakes be checked periodically (See
Daily Brake Performance Test on page 35).
To prevent severe injury or death
caused from driving a vehicle with
an improperly operating brake sys-
tem, the braking system must be properly main-
tained. All driving brake tests must be done in a safe
location with regard for the safety of all personnel.
TIRES
Tire condition should be inspected and inflation pressures
checked periodically while tires are cool (See PERIODIC
SERVICE SCHEDULE on page 133). Be sure to install
the valve dust cap after checking or inflating tire.
VEHICLE CLEANING AND CARE
Read and understand all instruc-
tions supplied by the manufacturer
of the pressure washer before use.
When pressure washing the exterior
of the vehicle, do not use pressure
in excess of 700 psi. Maintain a 12”
minimum distance from spray nozzle to painted sur-
face. To reduce the possibility of cosmetic damage,
do not use any abrasive or reactive solvents to
clean plastic parts.
Proper techniques and cleaning materials must be used
to prevent damage to the exterior of the vehicle. Using
excessive water pressure can cause severe injury to
operator or bystander. Excessive pressure can also
cause damage to seals, plastics, seat material, body fin-
ish, or the electrical system. Do not use pressure in
excess of 700 psi to wash exterior of vehicle.
Clean the windshield with water and clean cloth. Minor
scratches can be removed using a commercial plastic
polish or Plexus
®
plastic cleaner. Both are available from
the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with a
sponge or soft brush followed by and wiping with a damp
cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
INITIAL SERVICE CHART
Item
Service Operation
Battery Charger
Remove from vehicle and read operat-
ing instructions.
Batteries
Charge. Batteries must be fully
charged before initial use.
Seats
Remove protective plastic covering.
Brakes
Check operation; adjust if necessary.
Check hydraulic fluid level; add if nec-
essary.
Tires
Check air pressure; adjust if necessary.
Refer to WHEELS AND TIRES section
for inflation recommendations.
Vehicle Inspection
Visually inspect for leaks or damage
that may have occurred during ship-
ment from the factory.
Inspect for loose hardware; tighten if
necessary.
