38
MAINTENANCE
MAINTENANCE
PERIODIC MAINTENANCE CHECKLIST
ITEM
INTERVAL REFER TO
REMARKS
Air Filter
(660 cc Turbo)
2000 miles/
Seasonal
__
Replace
Brake System (Hydraulic)
Daily
Page 57
Check for binding, leakage, and proper operation;
lever firmness, travel, caliper, disc, and pads
Brake System (Mechanical)
Daily
Page 56
Check for binding, sticking, and proper operation;
lever travel, cable, spring, caliper, and disc
Cooling System - Liquid
Daily
Page 15
Check for leakage, damage, obstructions, coolant
level
Cooling System - Fan Belt
Monthly
Page 77
Check tightness and for wear, damage, and
obstructions
Charging System - Accessory Belt
(660 cc)
Monthly
Page 77
Check tightness and for wear, damage, and
obstructions
Oil System
Daily
Page 40-42
Check for leakage, damage, and injection/engine oil
level
Engine Oil
(660 cc Standard)
2500-3000
miles/
Seasonal
Page 41
Change oil and filter
Engine Oil
(660 cc Turbo)
2000 miles/
Seasonal
Page 41
Change oil and filter
Battery
Daily
Page 15
Page 53
Check for proper charge and tight connections
Stop Switch
Daily
—
Check for proper operation
Hoses
Daily
—
Check for damage, leakage, and routing
Headlight & Taillight/Brakelight
Daily
Page 71
Check for proper operation and cleanliness
Steering System
Daily
—
Check for proper operation, tightness of bolts, and
binding
Throttle Control System
Daily
Page 31
Check for binding, sticking, proper operation, throttle
cable tension, and routing
Drive Belt
Daily
Monthly
Page 61
Check for wear, cracks, and fraying
Check length and width dimensions
Ski Wear Bars
Daily
Page 74
Check for wear and damage
Carburetors - Main Jets - Adjustment
Screws
Daily
Weekly
Page 50
Page 42-50
Install proper main jets
Adjust according to specifications
Electrical Wiring
Weekly
—
Check for wear, damage, tight connections, and
routing
Exhaust System
Weekly
Page 14
Check for damage, leakage, and obstructions
Nuts, Bolts, Fasteners
Weekly
—
Check tightness
Recoil Starter
Weekly
—
Check rope for wear, fraying, and proper operation
Shock Absorbers
Weekly
Page 17
Check for fluid leakage and damage
Spark Plugs
(2-Stroke)
Weekly
Page 51
Check center electrode insulator color, carbon, and
gap
Suspension
Weekly
Page 67
Check for damage, loose components, and proper
adjustment
Track Tension/Alignment
Weekly
Page 64
Page 66
Check/adjust as necessary
Wear Strips
Weekly
Page 76
Check for wear and damage
Wires & Cables
Weekly
—
Check for wear, damage, and routing
Fuel System - Tank, Pump,
In-Line Filter, & Vent Hose
Weekly
—
Check for damage, wear, obstructions, and leakage
Fuel Filter
(660 cc)
5000 miles/
2 years
__
Replace
APV System
Monthly
Page 22
Check/adjust as necessary
Standard Chain Case
Monthly
Page 34
Check lube level and for leakage
ACT Drive Gear Case
Seasonal
Page 35
Change drive fluid prior to storage
Heat Exchangers
Monthly
—
Check for wear, leakage, and damage
Drive Clutch/Driven Pulley
Monthly
Page 15-16
Check for damage, abnormal noise, vibration,
binding, and sticking and clean off drive belt
deposits
Front & Rear Suspension
Monthly
Page 36
Grease