Maintenance and Adjustment
9-3
ITEM
MAINTENANCE INTERVAL (WHICHEVER
COMES FIRST)
REMARKS
Hours Frequency Miles (KM)
Routine Maintenance Check (performed at each interval below, whichever comes first)
Air filter 5 H - - Inspect; replace as needed
Brake pad wear 20 H Monthly 250 (402) Inspect periodically
Throttle Body Intake 20 H 1 M 250 (402) Inspect duct for proper sealing/air leaks
Battery
20 H
Monthly 250 (402) Check terminals; clean; test
Fuel System 25 H Monthly 250 (402) Check lines & fittings for leaks
General lubrication
25 H
3 M 250 (402) Lubricate all fittings, pivots, cables, etc.
Shift Linkage
25 H
3 M 250 (402) Inspect, lubricate, adjust
Engine Oil & Filter 50 H 6 M 500 (800) Replace
Steering 50 H 6 M 500 (800) Lubricate
Front / Rear Gearcase
Fluid
50 H 6 M 500 (800) Change Fluid
Front / Rear Stabilizer
Bars
50 H 6 M 500 (800) Lubricate and inspect bushings
Throttle Pedal/Cable 50 H 6 M 500 (800) Inspect for free movement & lubricate
Drive Belt 50 H 6 M 500 (800) Inspect; replace as needed
Antifreeze Coolant 50 H 6 M 500 (800) Pressure Test / Add Fluid
Tranmission Fluid 50 H 6 M 500 (800) Replace
Engine mounts 100 H 12 M 1000 (1600) Inspect; replace as needed
Cooling Hoses 100 H 12 M 1000 (1600) Inspect for cracks and leaks
Drive Shafts 100H 12M 1000 (1600) Remove and grease
Spark plug 100 H 12 M 1000 (1600) inspect; replace as needed
Clutches (Drive and
Driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Wiring 100 H 12 M 1000 (1600) Inspect for wear & routing
Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Shocks 100 H 12 M 1000 (1600) Check for oil leaks
Cam Chain Tensioner
100 H
12 M 1000 (1600) Check; replace as needed
Brake Fluid 100 H
12 M
1000 (1600) Change every two years
Suspension Components
100 H 12 M
1000 (1600) Inspect; replace if necessary
Spark arrestor
100 H
12 M - Clean out
Valve clearance 100 H
12 M
1000 (1600) Inspect; adjust
Extreme Maintenance Check (cut the Routine Maintenance Schedule in half)
*Service Note: Under extreme use, change gear case fluid every 25 hours. "Extreme Use" is defined as constant 4WD
op
eration on hilly or mountainous terrain, or if 4WD is the primary mode of operation.
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