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d) Pry out seals, and inspect bearings for wear or damage and replace if
necessary.
e) Pack the bearings with a NGLI grade #1 multi-purpose grease.
f) Insert (1) bearing, (1) new seal into the wheel.
NOTE: Seals (Exmark PN 103-0063) must be replaced.
g) If the axle assembly has had both spacer nuts removed (or broken loose),
apply a thread locking adhesive to (1) spacer nut and thread onto the axle with
the wrench flats facing outward. Do not thread spacer nut all of the way onto
the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of
the spacer nut to the end of the axle inside the nut.
h) Insert the assembled nut and axle into the wheel on the side of the wheel with
the new seal and bearing.
i) With the open end of the wheel facing up, fill the area inside the wheel around
the axle full of NGLI grade #1 multi-purpose grease.
j) Insert the second bearing and new seal into the wheel.
k) Apply a thread locking adhesive to the 2
nd
spacer nut and thread onto the axle with
the wrench flats facing outward.
l) Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to
20-25 in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.
m) Re-install the seal guards over the wheel hub and insert wheel into caster fork.
Re-install caster bolt and tighten nut fully.
IMPORTANT: To prevent seal and bearing damage, check the bearing
adjustment often. Spin the caster tire. The tire should not spin freely (more
than 1 or 2 revolutions) or have any side play. If the wheel spins freely adjust
torque on spacer nut until there is a slight amount of drag.
4.1.15 Lubricate brake handle pivot
:
Service Interval: 160 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Locate grease zerk under brake arm on left side of machine, pump until
grease oozes out of pivot.
4.1.16 Remove engine shrouds and clean cooling fins
:
Service Interval: 80 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust,
dirt and oil from external surfaces of engine, which can cause improper
cooling.
c) Make sure cooling shrouds are properly reinstalled. Operating the engine
without cooling shrouds will cause engine damage due to overheating.
4.1.17 Check spark plug
:
Service Interval: 160 hrs.
a) Remove spark plug, check condition and reset gap, or replace with new plug.
See Engine Owners Manual.
4.1.18 Change fuel filter
:
Service Interval: As Required
a) A fuel filter is installed between the fuel tanks and the engine. Replace when
necessary.
For Kawasaki engines use Kawasaki P/N 49019-7001