2-12
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure
rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, bolts, and cap screws are tightened
to specifications. For proper torque values, see Sec-
tion 10.
Ignition Timing
The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting
other components. To verify ignition timing, use the
following procedure.
NOTE: To check ignition timing, the seats and
center console must be removed.
1. Attach the Timing Light (p/n 0644-296) to the
spark plug high tension lead; then remove the
timing inspection plug from the left-side crank-
case cover.
2. Start the engine and using the RPM function on
the speedometer/tachometer (XT) or using a
suitable tachometer (Prowler), run at 1500
RPM; ignition timing should be 10° BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may
be damaged, the key may be sheared, the trigger coil
bracket may be bent or damaged, or the CDI unit
may be faulty.
Headlight/Taillight-
Brakelight
Each time the vehicle is used, lights should be
checked for proper function. With the ignition
switch in the ON position, select the high and/or low
beam on the light switch; the headlights and taillight
should illuminate. Test the brakelight by depressing
the brake pedal. The brakelight should illuminate.
HEADLIGHT
NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following pro-
cedure.
1. Remove the wiring harness connector from the
back of the headlight.
2. Grasp the bulb socket, turn it counterclockwise
and remove, and pull the bulb straight out of the
socket.
3. Install the new bulb into the socket and rotate it
completely clockwise in the housing.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the fol-
lowing procedure.
1. Remove the two machine screws and remove
the light assembly.
2. Rotate the bulb socket counterclockwise to
remove it from the light assembly; then pull
straight out on the bulb. Push the new bulb
straight into the socket.
3. Install the bulb and socket into the light assem-
bly and turn clockwise to lock in place.
4. Install the taillight-brakelight assembly on the
canopy support.
CHECKING/ADJUSTING
HEADLIGHT AIM
The headlights can be adjusted vertically. The geo-
metric center of the HIGH beam light zone is to be
used for vertical aiming.
1. Position the vehicle on a level floor so the head-
lights are approximately 6.1 m (20 ft) from an
aiming surface (wall or similar aiming surface).
NOTE: There should be an average operating
load on the vehicle when adjusting the headlight
aim.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
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