31
Maintenance
Periodic Maintenance Checklist
Item Interval Page Remarks
Brake System Daily 41 Check for binding, leakage, and proper operation;
lever firmness, travel, caliper, disc, and pads
Cooling System - Liquid Daily 14,35 Check for leakage, damage, obstructions, coolant
level
Oil-Injection System Daily — Check for leakage, damage, and injection/engine
oil level
Engine Oil (1100 cc Non-Turbo
Models)
2500 Mi/
Seasonal
33 Change oil and filter
Engine Oil (1100 cc Turbo Mod-
els)
2000 Mi/
Seasonal
33 Change oil and filter
Battery Daily 14,38 Check for proper charge and tight connections
Stop Switch Daily — Check for proper operation
Hoses Daily — Check for damage, leakage, and wear
Headlight & Taillight/Brakelight Daily 51-52 Check for proper operation and cleanliness
Steering System Daily — Check for proper operation, tightness of bolts,
and binding
Throttle Control System Daily 26 Check for binding, sticking, proper operation,
throttle cable tension, and wear
Drive Belt Daily
Monthly
44 Check for wear, cracks, and fraying
Check length and width dimensions
Ski Wear Bars Daily 52 Check for wear and damage
Electrical Wiring Weekly — Check for wear, damage, and tight connections
Exhaust System Weekly 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 17,49 Check for fluid leakage and damage and air pres-
sure (Fox Air Shocks)
Spark Plugs 3500 Mi 35 Check center electrode insulator color, carbon,
and gap
Valve Clearance (1100 cc Mod-
els)
5000 Mi/
Seasonal
37 Check/adjust
Suspension Weekly 48 Check for damage, loose components, and
proper adjustment
Track Tension/Alignment Weekly 46,47 Check/adjust as necessary
Wear Strips Weekly 53 Check for wear and damage
Wires & Cables Weekly — Check for wear, damage, and fraying
Fuel System - Tank, Pump, In-
Line Filter, & Vent Hose
Weekly — Check for damage, wear, obstructions, and leak-
age
Fuel Filter (1100 cc Models) 5000 Mi/
2 years
—Replace
Air Silencer (800 cc Models) Seasonal — Inspect/clean
Air Cleaner/Filter (1100 cc Turbo
Models)
Weekly/
Seasonal
32 Check/replace
APV System Monthly 22 Check/adjust as necessary
Chain Case Daily 29 Check lube level and for leakage
Chain Case - Lubricant Seasonal 29 Replace
Heat Exchangers Monthly — Check for wear, leakage, and damage
Drive Clutch/Driven Pulley Monthly 16 Check for damage, binding, and wear/remove
drive belt, clean drive clutch/driven pulley with
compressed air, and clean sheaves with suitable
parts-cleaning solvent
Rear Suspension Monthly 30 Grease