Maintenance Intervals

NOTE

The maintenance interval charts outline required maintenance and inspection based on estimated vehicle engine hours / miles. Each table states the number of hours / miles that service is required on the vehicle. Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes beyond 400 hours, return to the 25 hours chart and start the interval process over.

5 Hour / Break-in Service

Item		Remarks
XU	Engine Oil Change (Break-in)	Perform a break-in oil change at one month
	Drive Chain (Break-in)	Adjust and lubricate
XU D	Brake pad wear (Break-in)	Inspect periodically

10 Hour / 160 km (100 mile) Service

Item		Remarks
D	Valve Clearance (Break-in)	Valve lash adjustment: Every 50 hours after first 10–hour adjustment

25 Hour / 400 km (250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Engine Oil Change

50 Hour / 800 km (500 mile) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment: Every 40 hours after first 10-hour adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
XU	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

75 Hour / 1200 km (750 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

100 Hour / 1600 km (1000 mile) Service

Item		Remarks
	Battery	Check terminals; clean; test
XU	Transmission (Main Gearcase)	Replace transmission fluid
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks
D	Fuel System / Filter	Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
XU	Spark Plug	Inspect; replace as needed
XU	Engine Mounts	Inspect
	Exhaust Muffler / Pipe	Inspect
XU	Wiring	Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
D	Clutches (Drive and Driven)	Inspect; clean; replace worn parts
	Drive belt	Inspect; replace as needed
D	Front wheel bearings	Inspect; replace as needed

125 Hour / 2000 km (1250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

150 Hour / 1500 mile (2400 km) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

175 Hour / 2800 km (1750 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

200 Hour / 3200 km (2000 mile) Service

Item		Remarks
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks
D	Fuel System / Filter	Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
XU	Spark Plug	Inspect; replace as needed
XU	Engine Mounts	Inspect
	Exhaust Muffler / Pipe	Inspect
XU	Wiring	Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
XU	Clutches (Drive and Driven)	Inspect; clean; replace worn parts
	Drive belt	Inspect; replace as needed
D	Front wheel bearings	Inspect; replace as needed
D	Brake fluid	Change every two years

225 Hour / 3600 km (2250 mile) Service

Item		Remarks
	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change

250 Hour / 4000 km (2500 mile) Service

Item		Remarks
XU	Fuel System	Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
	Battery	Check terminals; clean; test
XU	Main Gearcase Oil	Inspect level; change yearly
XU	Engine Oil Change
D	Valve Clearance	Valve lash adjustment
XU	General Lubrication	Lubricate all fittings, pivots, cables, etc.
	Shift Linkage	Inspect, lubricate, adjust
D	Steering	Lubricate
XU	Front Suspension	Lubricate
XU	Rear Suspension	Lubricate
	Throttle Body Intake Duct	Inspect duct for proper sealing/air leaks

2020 ACE 150 P/N 9930636