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Maintenance
Figure 12
1. Seal guard 2. Spacer nut with wrench
ats
2. Remove caster wheel from caster forks.
3. Remove seal guards from the wheel hub.
4. Remove one of the spacer nuts from the axle
assembly in the caster wheel. Note that thread
locking adhesive has been applied to lock the
spacer nuts to the axle. Remove the axle (with
the other spacer nut still assembled to it) from
the wheel assembly.
5. Pry out seals, and inspect bearings for wear or
damage and replace if necessary.
6. Pack the bearings with a NGLI grade #1
multi-purpose grease.
7. Insert one bearing, one new seal into the wheel.
Note: Seals (Exmark PN 103-0063) must be
replaced.
8. If the axle assembly has had both spacer nuts
removed (or broken loose), apply a thread locking
adhesive to one spacer nut and thread onto the
axle with the wrench ats facing outward. Do
Not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8 inch (3 mm)
from the outer surface of the spacer nut to the
end of the axle inside the nut.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
10. With the open end of the wheel facing up, ll
the area inside the wheel around the axle full of
NGLI grade #1 multi-purpose grease.
11. Insert the second bearing and new seal into the
wheel.
12. Apply a thread locking adhesive to the 2nd spacer
nut and thread onto the axle with the wrench ats
facing outward.
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,
then re-torque to 20-25 in-lb (2-3 N-m). Make
sure axle does not extend beyond either nut.
14. Reinstall the seal guards over the wheel hub and
insert wheel into caster fork. Reinstall 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.
Reapply thread locking adhesive.
Remove Engine Shrouds and
Clean Cooling Fins
Service Interval: Every 80 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove cooling shrouds from engine and clean
cooling ns. Also clean dust, dirt, and oil from
external surfaces of engine which can cause
improper cooling.
3. Make sure cooling shrouds are properly
reinstalled. Operating the engine without
cooling shrouds will cause engine damage due to
overheating.
Check Spark Plugs
Service Interval: Every 160 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owners
Manual.
Change Fuel Filter
Service Interval: As required
A fuel lter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
Replacement Filters
Kawasaki
Kawasaki P/N
49019–7001
27