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 / 100 mile (160 km) Service
| Item | Remarks | |
|---|---|---|
| D | Valve Clearance (Break-in) | Valve lash adjustment: Every 50 hours after first 10–hour adjustment |
25 Hour / 250 mile (400 km) 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 / 500 mile (800 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: 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 / 750 mile (1200 km) 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 / 1000 mile (1600 km) 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 / 1250 mile (2000 km) 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 / 1750 mile (2800 km) 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 / 2000 mile (3200 km) 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 / 2250 mile (3600 km) 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 / 2500 mile (4000 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 | |