5. Tighten. All tightening operations should be performed with sufficient wrench‐torque (force on the wrench handle) to tighten the nut according to good mechanical practice. Use torque‐indicating wrench where specified. Do not overtighten, as this may strip threads, or cause distortion. Tightening will always be understood to include the correct installation of lock washers, lock nuts, and cotter pins provided to secure the tightening.
(e) When conditions make it difficult to perform the complete preventive maintenance procedures at one time, these can sometimes be handled in sections, planning to complete all operations within the task if possible. All available time at halts and in bivouac areas must be utilized, if necessary, to assure that maintenance operations are completed. When limited by the tactical situation, items with special services in the columns should be given first consideration.
(f) The numbers of the preventive maintenance procedures that follow are identical with those outlined on W.D. AGO Form No. 463, which is the Preventive Maintenance Service Work Sheet for Motorcycles. Certain items on the work sheet that do not apply to this vehicle are not included in the procedures in this manual. In general, the numerical sequence of items on the work sheet is followed in the manual procedures, but in some instances there is deviation for conservation of the mechanic’s time and effort.
(5) Specific Procedures. The procedures for performing each item in the 1,000‐mile maintenance procedures are described in the following chart. Each page of the chart has a column at its left edge corresponding to the 1,000‐mile maintenance.
ROAD TEST
| 1000 Mile Maintenance | NOTE: If tactical situation does not permit a full road test, performitems 2, 3, 4, 5, 6, 7, 8, 9, 12, and 14, which require slight or nomovement of the vehicle. When a road test is possible, it should be forpreferably 5, and not over 10 miles. |
|---|---|
| 1 | Before‐operation Inspection. Perform Before‐operationService listed on W.D. Form No. 418. “Driver’s Trip Ticket andPreventive Maintenance Service Record” (described in par. 15), todetermine if vehicle is in a satisfactory condition to make theroad test safely. |
| 2 | Ease of Starting. Start engine and observe action ofstarter. Note if engine responds readily. |
| 3 | Oil Circulation. Oil circulation is normally indicated byoil signal light (red light) in instrument panel being out. Whenred light is on, oil is not circulating. Observe for excess smokein exhaust. CAUTION: If red light fails to go out after enginehas been started, stop engine at once. Refer to paragraph [30] forpossible causes. |
| 4 | Instruments. Observe instruments for proper or normalindication and functioning of system to which they apply. |
| Speedometer and Odometer. Speedometer must indicatevehicle speed without excessive noise or fluctuation; odometer mustrecord trip and total mileage. Oil Pressure Signal Light.Note whether oil signal light (red light) indicates correctly.After ignition switch is turned on, and before starting engine, thered light should go on, indicating no oil circulation. When engineis started, light should go out. | |
| Generator Signal Light. With switch on, and beforestarting engine, the green signal light should go on, indicatingdischarge of battery. After starting engine, increase enginespeed to a medium fast idle; green signal light should then goout, indicating generator is charging battery. CAUTION: Continueobservation of signal lights during road test, and if lights shouldfail to operate as indicated above, stop engine, investigate cause,and correct or report trouble to proper authority. | |
| 5 | Brake Operation. Test foot brake for safe stop withinreasonable distance. Note squeaks or chatter that might indicatewet, oily, dirty, or loose lining, damaged drum, or improperadjustment. Apply hand‐operated front brake only in conjunctionwith rear brake and observe whether it operates effectively inassisting to make a quicker stop. |
| 6 | Clutch Operation. Before moving vehicle, make sure thatclutch pedal has satisfactory free travel before it begins todisengage clutch; that it releases clutch completely beforereaching end of travel; and that there are no unusual noises inclutch‐release mechanism. When starting vehicle, observe whetherclutch grabs, chatters, or slips when fully engaged. |
| 7 | Gearshift. Shift through entire gear range of transmissionand observe whether mechanism operates freely without clashing orjumping out of gear. Note any unusual vibration that might indicateloose engine or transmission mountings. |
| 8 | Unusual Noises. During entire road test, listen for unusualnoises that might indicate worn, loose, damaged, or insufficientlylubricated parts in the entire motorcycle, particularly in engineand accessories, or in the power train. CAUTION: Loose primary (front) drive chain, with slack in excessof ½ inch total up‐and‐down motion, can cause excessive noise whichsounds like engine knock. Remove inspection cover for examinationof chain. |
| 9 | Steering. Observe steering mechanism for indication oflooseness or excessive binding through full turning range. Withhands resting lightly on handle bars and vehicle in verticalposition, observe whether there is any tendency to pull to oneside when operating at a reasonable speed. Note any indication ofsteering instability at higher speeds. |
| 10 | Balance. If vehicle does not balance properly in operation,inspect for misalinement of rear wheel. |
| 11 | Speedometer and Odometer. Inspect speedometer for properoperation, excessive fluctuation, or unusual noise. Observeodometer for correct recording of trip and total mileage. |
| 12 | Throttle and Spark Controls. Set throttle stop screw and lowspeed needle adjustment so that engine will operate smoothly andwill not stall at idling speed. With vehicle running at a speed of30 miles per hour, or faster, in high gear, turn throttle controlgrip to “OPEN” and “CLOSED” positions and note whether engineresponds instantly to throttle changes. Turn spark control grip andnote whether it fully advances and retards ignition timer. |
| 13 | Power and Operation. Observe engine for normal pullingpower, and good operating characteristics in each speed, from firstto high gear. Also observe whether engine misses, stalls, knocksexcessively, or makes any other unusual noise. |
| 14 | Carburetor Adjustment. No carburetor adjustment, otherthan idle adjustment as performed in item 12, is required on thisvehicle. |
| 15 | Brake Drum and Hub Temperature. Immediately after completingroad test, feel front and rear brake drums and wheel hubs foroverheating. |
| 16 | Power Train Temperatures. Feel transmission for overheating. |
| MAINTENANCE OPERATION | |
| 17 | Compression Test. With throttle wide‐open, test compressionwith starter. If engine lacks compression, inspect for leaks. |
| 18 | Transmission. Inspect transmission for good condition,secure mounting, and leaks. Inspect oil level. Drain and refilltransmission to level of transmission filler plug opening withspecified grade of engine oil. CAUTION: Always drain transmissionimmediately after it has been warmed and agitated by operation ofengine. Refill as soon as draining is completed to avoid hazardof operating without lubricant. Tighten all mounting and assemblybolts securely. |
| 20 | Engine Oil. Inspect oil tank for oil level: drain and refilltank. CAUTION: Fill to within 1 inch of filler opening and fillercap with specified weight of oil. Always drain immediately afterengine operation and refill as soon as draining is completed, toavoid hazard of operating without lubricant. |
| 21 | Battery and Carrier. Clean top of battery. See that batteryand carrier are in good condition, and that carrier is securelymounted. Remove cell caps: make sure that vents are open. Testspecific gravity with hydrometer and record readings on work sheet,W.D. AGO Form No. 463. Readings below 1.225 indicate need forrecharge, or battery failure. Variation between cells of more then0.025 must be reported. Read and record voltage of battery (6‐voltreading is normal). Bring electrolyte to 5⁄16 inch above tops ofplates, using clean, drinkable water. If excessive looseness ofbattery in case is noted, check for presence of rubber pad inbottom of case, and make sure rubber pad is installed on top ofbattery, when battery service is completed. |
| 22 | Battery Wires and Terminals. Inspect battery for goodcondition and secure connections. Look for worn spots in wireinsulation. Oil the felt washers on battery terminals. |
| 23 | Electrical Wiring. Inspect all electric wiring to see that itis in good condition, securely attached, and connected. Look for wornspots in insulation. |
| 24 | Generator Drive and Mounting, and Relay. Inspect generatorfor secure mounting. After removing left footboard assembly,remove generator and cover. Examine commutator for cleanliness,good condition, or excessive wear. If commutator is dirty, it mustbe cleaned with No. 00 sandpaper. Blow out with compressed air.If commutator is in bad condition or excessively worn, replacegenerator. Remove relay cover, being careful to avoid damage tomechanism, and inspect for cleanliness. Blow out with air if wet ordirty. CAUTION: Do not attempt to adjust relay, or to clean it inany other manner. |
| 25 | Timer (Circuit Breaker). Clean and remove timercover. See that wiring leads are securely connected and that insideof the timer is clean. Inspect breaker points to see that theyare clean, well‐lined, engaging squarely, and are not excessivelypitted, burned, or worn. See that condenser mounting screw istight. Breaker lever should be free on its pivot and well insulatedfrom the pivot pin. Determine if breaker arm spring exerts normalforce against arm. Examine camshaft by hand‐feel to see whetherit is excessively worn in its bushings; if camshaft bushings areworn excessively, install new timer. If points are slightly burnedor pitted, dress them with a fine file. If breaker points areunserviceable, install a new set, taking care to aline them andto adjust gap to 0.022 inch. Apply one drop of oil to breaker armpivot pin. Use clean cloth to wipe cam and then coat with a verylight film of light grease. CAUTION: Be careful to avoid gettingoil or grease on breaker points. |
| 26 | Spark Plugs. Remove spark plugs, clean with sandblastcleaner, and inspect for cracked insulators: inspect electrodesfor good condition and adjust gap to 0.025 to 0.030 inch; replacefaulty plugs. Be sure to install new gasket with new plug. Inspectradio suppressors on plug cables for good condition and secureattachment. |
| 27 | Ignition and Light Switch. Make sure that the switch is ingood condition and operating properly in all positions. |
| 28 | Lights, Service and Blackout. See that all lights are clean,in good condition, properly aimed, and securely mounted. Tacticalsituation permitting, turn switch to each of its positions andobserve whether service and blackout lights operate properly,and whether they go out when switched off. Operate dimmer switchon left handle bar to see whether it depresses beam of serviceheadlight. Apply foot brake for check of both blackout and servicestop light operation. Inspect lenses for breakage, and headlightreflector for discoloration. Clean all lenses. |
| 29 | Horn. Tactical situation permitting, sound horn to test fornormal signal. Examine horn for good condition, secure mounting,and tight wiring connections. |
| 30 | Cylinder Heads. If cylinder head gaskets show signs ofleakage, tighten head bolts: if leakage persists, new gasketsshould be installed. A head bolt wrench (Fed‐Stock No. 41–W–1525)is available with which head bolts can be tightened withoutremoving tanks for wrench clearance. If tanks are removed topermit taking off heads and installing new gaskets, bolts shouldthen be tightened evenly with a torque wrench to a tension of 60foot‐pounds minimum, or 65 foot‐pounds maximum, when engine is cold. |
| 31 | Cylinder Hold‐down Nuts. If these nuts are loose, or thereis excessive oil leakage around cylinder bases, tighten nuts evenlywhen engine is cold. If excessive leakage persists, new gasketsshould be installed. CAUTION: If cylinder base nuts are loose,perform item 36 before starting engine. |
| 32 | Engine Mountings. Inspect top engine mounting bracket andbolt for good condition and security. CAUTION: Tight seating ofthe engine bracket mounting bolt is a necessity for effective radiobonding. Inspect four lower engine mounting bolts for signs oflooseness. Tighten as required. |
| 33 | Engine Crankcase. Examine engine crankcase for goodcondition and for leaks. Make sure timing gear cover screws, andoil feed and scavenger pump nuts, are tight. |
| 34 | Intake Manifold. Examine manifold for good condition andsecure mounting. Make sure manifold nuts are tight. |
| 35 | Muffler and Exhaust Pipes. Inspect muffler and exhaust pipesfor good condition, secure mounting, and for leaks. Be sure tailpipe opening is not restricted. |
| 36 | Valve Mechanism. When engine is cold, adjust valve tappetclearance to 0.004–inch minimum, 0.005–inch maximum on intakevalve; 0.006–inch minimum, 0.007–inch maximum on exhaust valve. Seethat valve springs are in good condition and properly secured; thatvalve tappet adjusting screws and lock nuts are in good condition;and that valve covers are in good condition, secure, and notleaking oil. |
| 37 | Starter. Examine pedal, crank, and return spring for goodcondition, correct assembly, and secure mounting. Starter shouldoperate without binding, and return spring should bring startercrank to its disengaged position when foot pressure is removed.CAUTION: Make sure that starter crank pinch bolt is installedwith head of bolt toward rear of vehicle when crank is in uprightposition. |
| 38 | Engine Cooling Fins. Inspect engine cooling fins for goodcondition and cleanliness. Remove all dirt or foreign matter. Donot apply paint to cooling fins. |
| 39 | Filler Caps and Vents. Wipe dirt and dust from filler capsof fuel and oil tanks. Inspect caps and gaskets to see that theyare in good condition. Note whether vent in fuel filler cap isopen. Reinstall caps, observing that each locks properly on fillerneck. Do not interchange fuel and oil tank filler caps. |
| 40 | Fuel Tank Valves and Lines. See that valves and lines are ingood condition, secure, and not leaking. Test fuel shut‐off valve forample friction to hold valve in reserve position. See that valve liftsfreely enough to operate satisfactorily. |
| 41 | Oil System Leaks. Examine oil tank, oil lines, vent line,and connections for good condition, secure attachment, and forleaks. |
| 42 | Carburetor and Fuel Filter (Gasoline Strainer).Examine carburetor and fuel filter for good condition, secureconnections, and for leaks. Shut off fuel tank valve and removefilter (strainer) cap and screen. Wash cap and screen indry‐cleaning solvent, and open shut‐off valve slightly to flushfilter body. Reassemble screen, gaskets, and cap, being careful notto damage gaskets. Use new gaskets if necessary. Drain water andforeign matter from carburetor bowl by removing bowl drain plug.Open shut‐off valve slightly to flush carburetor bowl while plug isout. Replace plug, being careful to avoid crossing threads. Openfuel tank shut‐off valve and check for leaks. |
| 43 | Air Cleaner. Remove oil cup; inspect condition of oil, andamount of sediment. If service is required, remove filter elements,clean and fill cup to NORMAL level. Wash elements in dry‐cleaningsolvent, dry thoroughly with compressed air, immerse each elementin oil in cup, and reassemble elements and oil cup to air cleanerbody immediately. Make sure gaskets are in good condition. NOTE:Early type round cleaner does not have removable filter element;therefore, the complete cleaner body must be removed to washelement. |
| 44 | Gearshift Lever and Linkage. See that gearshift leverand linkage are in good condition, secure, and not excessivelyworn. Lubricate all joints with a few drops of engine oil. Adjustshifter lever so that when moved to any gear position in shifterguide on tank, the transmission is shifted to full engagement incorresponding gear. |
| 45 | Primary Drive. Remove inspection hole cover from front chainguard. With clutch engaged and transmission in neutral, rotateprimary chain to position of least slack. Check chain for ½–inchdeflection. Deflection measurement should be total up‐and‐downfree movement. Inspect chain for adequate lubrication. Loosen frontand rear chain oiler adjusting screws two turns each. Do not removescrews. Idle engine 1 minute, then tighten screws firmly, but donot force. This operation serves to flush control valves and rearchain oiler pipe. |
| 46 | Clutch Pedal and Linkage. Inspect clutch pedal clevis connectionsand cable to see that they are in good condition and notexcessively worn. Check free travel of clutch pedal to make sureit is within specified limits. With foot pedal in fully disengagedposition (heel against footboard) clutch release lever must clearsprocket cover stud and nut by about 1⁄16 inch: with foot pedal infully engaged position, clutch release lever must have between 1⁄8–and ¼–inch of free movement on end of foot pedal cable. Lubricateall joints with a few drops of engine oil, including cable at eachend of cable housing. |
| 47 | Rear Chain and Guard. Inspect rear chain guard for good conditionand secure mounting. Remove chain, wash thoroughly in dry‐cleaningsolvent, and hang it up to dry. See that chain is in goodcondition, not excessively worn, and has no broken rollers on sideplates. Soak chain in SAE 10 engine oil for a short period of timeto allow oil to penetrate into all rollers; drain chain, and wipeoff excess oil. Inspect countershaft sprocket, and rear wheelsprocket to see that they are in good condition, not excessivelyworn, and that rear sprocket rivets are tight. Do not reinstallchain until item 71 has been performed. When reinstalling chain,make sure that connecting link is in good condition and securelylocked. See that open end of connecting link spring clip istrailing in direction of chain travel. Adjust chain (paragraph [60]). |
| 48 | Final Drive Sprockets. Inspection of final drive sprockets is madewhen performing item 47. |
| 50 | Paint and Markings. Examine vehicle for good condition and see thatpaint is not rubbed to a polish, and has no bare spots that mightrust or reflect light. See that vehicle markings are legible. |
| 51 | Frame. Examine frame for good condition; observe whether it seemsto be sprung out of alinement. |
| 52 | Steering Head and Fork Stem. Raise front end of vehicle by placingblocks under skid plate. Complete all following items to andincluding item 71, before lowering vehicle to ground. Examinesteering head and fork stems for good condition. Note whetherthere is up‐and‐down play caused by loose bearings. Move handlebars through complete range and observe if there is any bindingwhich might indicate improperly adjusted or defective bearings. |
| 53 | Handle Bars. Examine handle bars for good condition andsecure mounting. |
| 54 | Throttle Control. See that grip is in good condition, thatthrottle opens and closes completely as grip is turned to itsextreme positions, and that control wire and housing are in goodcondition and secure. Lubricate lightly through hole in rear ofgrip to avoid rusting and “freezing.” If grip does not rotatefreely, disassemble grip, clean, and lubricate spiral control parts. |
| 55 | Spark Control. See that grip is in good condition, thatspark is fully advanced and retarded as the grip is turned to itsextreme positions; that the control wire and housing are in goodcondition and secure. Lubricate lightly through hole in rear ofgrip to avoid rusting and “freezing.” If grip does not rotatefreely, disassemble grip, clean, and lubricate spiral control parts. |
| 57 | Rear View Mirror. Clean rear view mirror and examine forgood condition and secure mounting. |
| 58 | Front Fender (Mudguard). Examine front fender forgood condition and secure mounting; see that fender does not scrapetire. |
| 59 | Weapon Carrier. Inspect weapon carrier for good conditionand secure mounting. |
| 60 | Ammunition Box. See that ammunition box and cover are ingood condition and securely attached. |
| 61 | Front Springs. See that front springs and their mountingsare in good condition, correctly assembled, and secure. |
| 62 | Front Forks. See that front forks are in good condition andsecurely mounted. |
| 63 | Front Fork Rocker Plates (Rocker Arms). See that front forkrocket plates are in good condition, secure, and not excessivelyworn. Tighten rocker plate stud nuts securely. |
| 64 | Front Fork Damper. Inspect steering damper for goodcondition and to see that it operates freely. Observe whetherfriction disks are glazed, coated with grease, or excessively worn. |
| 65 | Front Brake and Control Linkage. See that control linkageoperates freely, that all connections are tight, and that brake isadjusted so that end of hand lever has ¼ free travel before meetingresistance. Look for any indications of a cracked or excessivelyworn brake drum: badly worn, loose, or grease‐saturated linings. Ifthere are any such indications, remove wheel for closer inspection.Look for badly worn brake side cover bushing, shackle bushings andstuds, or brake operating stud bearing. Apply a few drops of engineoil to control cable, especially at control housing oiler at lefthandle bar, and to pin joints. |
| 66 | Front Wheel Alinement and Spokes. Examine front wheel spokesfor presence, good condition, and tightness. If loose spokes arefound, tighten evenly, taking care not to distort rim out‐of‐round,or to cause run‐out. Examine rim for good condition, and spin wheelto see that it has no appreciable run‐out. |
| 67 | Front Wheel Bearings. Inspect wheel to see whether bearingsare excessively loose. Wheel should have slight amount of sideplay at rim. Spin wheel and listen for unusual noises whichmight indicate dry or defective bearings or races. Observe forexcessive grease leak. If wheel is found to need only slight conereadjustment to correct excessive bearing play, remove wheel andmake this adjustment (par. [126]). If indications are found that hubis otherwise in bad order, replace wheel. |
| Each Sixth 1,000–Mile Maintenance Service. Remove frontwheel, axle sleeve and bearing, and, together with wheel hub,clean thoroughly in dry‐cleaning solvent. Inspect parts for goodcondition: inspect brake drum. Inspect lining for good conditionand secure attachment, and see that it is neither excessively wornnor soaked with grease. Repack bearings, hub, and axle sleeve withspecified lubricant. CAUTION: Make sure that hands and grease areperfectly clean, and that grease is forced between balls onto thecone. Reassemble and adjust bearings according to instructions inparagraph [126], taking care to see that wheel is properly alined.If unusual operating conditions, such as fording streams, haveindicated probable contamination of lubricant, this service shouldbe performed more frequently. | |
| 68 | Front Wheel Axle Nuts. Tighten axle nuts, making surethat cotter pins are installed. Slot in stabilizer plate must beanchored on extended end of left‐front rocker plate stud. |
| 69 | Tires, Front and Rear. Gage tires and inflate to 18 poundsfront, and 20 pounds rear (cold). Make sure that valve stems arein good condition and correctly installed, and that valve caps arepresent and secure. Examine tires for cuts, bruises, breaks, andblisters: remove imbedded glass, nails, or other foreign matterfrom tire treads; observe treads for excessive or irregular tirewear. At any inspection when unusual or irregular tire wear becomesevident, interchange front and rear tires. |
| 70 | Rear Wheel Alinement and Spokes. With vehicle on rear stand,inspect in same manner as front wheel (item 66). If it is necessaryto aline wheel in frame, make sure sprockets and chains are incorrect alinement. |
| 71 | Rear Wheel Bearings and Seals. Inspect wheel to see whetherbearings are excessively loose (wheel should have a slight amountof play at rim). Spin wheel and listen for unusual noise whichmight indicate dry or defective bearings. Also observe whetherthere is excessive grease leak. Test for excessive end play. Ifwheel is found to have considerable side play at rim, indicatingexcessively worn bearings, or there is evidence of hub assemblybeing in bad order otherwise, replace wheel. If wheel must bereplaced, inspect brake drum and lining for good condition, asindicated in item 75, before reinstalling wheel. CAUTION: Makesure that wheel mounting socket screws are tight. |
| 72 | Rear Wheel Axle Nut. See that rear wheel axle nut is in goodcondition and securely tightened. |
| 74 | Rear Fender (Mudguard). Inspect rear fender for goodcondition and secure attachment. |
| 75 | Rear Brake and Control Linkage. See that brake controllinkage operates freely, and that all connections are secure. Lookfor indications of badly worn or grease‐saturated linings. If brakeoperating lever stands considerably ahead of vertical, excessivelining wear is indicated. If grease has worked out between brakedrum and brake cover, grease‐saturated linings are indicated. Ineither case the wheel should be removed for closer inspection.Inspect drum for cracks or excessive wear. Make sure wheel mountingsocket screws are tight. Examine linkage for loose or worn pin orclevis, and for missing washers or cotter pins. Apply a few dropsof engine oil to all linkage joints. Brake pedal should have 1–inchfree travel before brake begins to meet resistance. Adjust lengthof brake rod at brake operating lever to provide 1–inch free pedaltravel. |
| 77 | Footboard and Rest. Examine footboard and rest for goodcondition and secure attachment. |
| 78 | Saddle Spring and Hinge. Examine saddle for good conditionand secure mounting, paying particular attention to torn leather,ripped seams, sagging or broken spring in seat post, and excessivewear in front hinge. CAUTION: Make sure that spring wire clipproperly locks the saddle rear hinge clevis pin. |
| 79 | Luggage Carrier. Examine luggage carrier for good conditionand secure mounting. |
| 80 | Saddle Bags. Examine saddle bags for good condition,cleanliness, and secure fastening to luggage carrier. Noteparticularly whether leather is torn, seams ripped, or straps andbuckles missing or damaged. |
| 81 | Tools, Tire Pump, and Equipment. Inspect tool kit, tools,tire pump, and other equipment for good condition, cleanliness,serviceability, and proper stowage. Make sure that tire pump issecurely clamped to motorcycle frame. Check all items with stowagelist (pars. [21], [22] and [23]). Make sure that vehicle manuals andAccident Report Form No. 26 are present on vehicle and legible. |
| 82 | Safety Guards. Inspect safety guards for good condition andsecure mounting. |
| 83 | Leg Shields. Inspect leg shields for good condition andsecure mounting. NOTE: Motorcycles operating in warm weathershould not be equipped with leg shields, as they seriously hamperengine cooling. |
| 84 | Skid Plate. Examine skid plate for good condition and securemounting. CAUTION: Skid plate must be present. |
| 85 | Vehicle Lubrication. Lubricate all points of vehicle inaccordance with instructions in this manual, Lubrication Guide,current lubrication bulletins or directives, and the followinginstructions: |
| Any unit that required disassembly for inspection purposes mustbe lubricated correctly unless the vehicle is to be deadlinedfor the repair of that unit. Use only clean lubricant. Keep alllubricant containers covered except when used during lubrication.Before applying lubricant, always wipe dirt from the lubricationfitting or plug so that dirt will not enter with the lubricant.If lubricant fittings or plugs are missing or damaged, replacethem. Clean the hole in which the fitting is to be installed, andlubricate after the new fitting has been installed. | |
| Lubricant must be applied properly. On unsealed joints or bushings,apply lubricant until it appears at openings. However, lubricatesparingly the front wheel hub, rear wheel hub, front brake sidecover bushing, front brake operating lever stud, and rear brakeoperating lever stud, to prevent grease reaching brake linings.Rider should be advised whenever wheel bearings are serviced oradjusted, so that during the next road operation he may determinewhether bearings or brake drums are running hot, due to overtightadjustment of bearings, or a dragging brake. | |
| Do not apply more than specified amount of lubricant to generatoror timer (circuit breaker). To do so may cause failure of the unit. | |
| Wipe off excess applied lubricant that may drip onto brake oroperating surfaces, soil clothes, or detract from vehicle’sappearance. | |
| Parts or assemblies that have already been lubricated whiledisassembled for inspection, gear cases that have been drained andrefilled as mandatory items in the procedure, and those parts thathave been indicated for special lubrication, will be omitted fromthe general lubrication of the vehicle. | |
| 86 | Final Road Test. Make a final road test, reinspectingitems 2 to 16, inclusive. Be sure to recheck transmission to seethat lubricant is at correct level and not leaking. Confine thisroad test to the minimum distance necessary to make satisfactoryobservation. Correct or report all deficiencies found during finalroad test to designated authority. |
Section IX
ORGANIZATION TOOLS AND EQUIPMENT
| Paragraph | |
|---|---|
| Tools and equipment | [27] |