Race Prep M Check tires for holes and cuts Set tire pressure Check for stem cap Check valve stem Replace tires Check wheels for damage Torque

Transcription

1 Race Prep M Check tires for holes and cuts Set tire pressure Check for stem cap Check valve stem Replace tires Check wheels for damage Torque bead rings to 100 inch lb. Torque lug nuts to 35 ft lb Grab top and bottom of tire and check wheel bearings Lube wheel bearings Replace wheel bearings Check spindle cotter pin Check front brake pad wear Check for brake drag Rebuild calipers Torque brake line banjo bolts 120 in lb Inspect brake lines for wear Inspect brake line attachments Torque caliper to spindle bolts Check front wheel rock guard mounting tabs Check ball joints for wear pull up and down at ball joint Oil ball joints Replace ball joints Torque ball joint to spindle nuts 60 ft lb Measure Camber -.5 negative at top using builders square Torque ball joint to a arm nuts and bolts 75 ft lb Check tie rod ends for wear grab and move up and down Replace tie rod ends Check toe 3/16 inch in per side using string method Inspect a arms for bends and cracks Torque a arms to frame bolts 32 ft lb Check upper a arm for bushing wear Replace upper a arm bushings Replace lower a arm bushings Grease a arm bushings Check shock end bearings for wear Lube shock bearings Replace shock bearings Inspect shock for leaks or eternal damage Check shock action push up and down on the quad Rebuild shocks Check ride height Torque Upper shocks bolts to 32 ft lb Torque Lower shock bolts to 40 ft lb Install shock covers

2 Torque tie rod end to spindle nuts 32 ft lb Torque tie rod end to steering stem nuts 32 ft lb Verify cotter pins in all 4 tie rod ends Torque tie rod end to tie rod nuts 32 ft lb Torque bumper bolts 22 ft lb Check steering stabilizer linkage bushings for wear Check steering stabilizer for leaks Check steering stabilizer linkage angle to mounts 90 degrees Check steering stabilizer for sufficient dampening adjust or rebuild as needed Rebuild steering stabilizer Torque steering stabilizer mount bolts 6mm 100 in lb Torque steering stabilizer mount bolts 8mm 22 ft lb Torque steering stabilizer linkage bolts 90 in lb Check steering stabilizer linkage for free movement Check lower steering stem bearing Replace lower steering stem bearing Check upper steering stem bushing for free movement loose is good Replace upper steering stem bushing Torque Lower Steering stem Nut 70 ft lb Verify Steering stem cotter pin Inspect steering flag for bends, cracks, or any damage Inspect steering stops for bends or cracks Inspect key switch for smooth operation and free from dirt Inspect kill switch for correct operation Replace Kill switch Remove front plastic and inspect all wiring Clean out on/off bar switch Replace on/off switch Clean and inspect radiator Check coolant level diagnose problem if low!!!! Install front plastic with correct fasteners torque to 80 in lb Use correct coolant to set coolant level in recovery bottle Inspect coolant hose from radiator to rezy Inspect Coolant hose from overflow at rezy verify that its open Inspect coolant fan for free movement Inspect coolant fan for turning on at the correct temp Inspect all coolant hoses for wear or any other damage Inspect hose clamps replace any that have been overtightened Torque engine mount bolts to 34 ft lb Torque ehaust bolts at head to 20 ft lb Inspect header flange for warpage Torque ehaust mounting bolts to 22ft lb Inspect ehaust clamp Inspect for ehaust packing burnout Repack ehaust Inspect Clutch Fibres

3 Replace Clutch Fibres Replace clutch Steels Replace clutch springs Replace Cutch Bolts Torque Clutch bolts to 80 in lb Torque clutch cover bolts to 80 in lb Change engine oil Replace oil filter Inspect oil and filter for debris Torque oil drain bolt to 30 ft lb Replace crush rings Check valve clearance if engine ingested dust or mud check intake tube Check valve clearance Replace valves anytime they are too tight after a race Replace top end Replace timing chain Measure rod rock- replace crank if over.060 Inspect engine for leaks or damage Inspect coil to plug grip Replace coil Install coil hold down foam Inspect fuel tank for leaks, cracks, or wear Inspect fuel tank for dirt Flush out fuel tank Inspect foot pegs for damage Replace foot pegs Torque foot peg bolts to 34 ft lb Torque Swingarm bolt to 65 ft lb Remove and lube swingarm bolt Replace swingarm bearings Inspect heel guards for damage Torque heel guard mounting bolts Torque brake lever to frame bolt to 32 ft lb Inspect brake pedal for damage Inspect brake pedal for height adjustment level Torque Master Cylinder bolts to 90 in lb Inspect rear brake line for damage and that it is secured Inspect rear hub to ale fit repair if loose Inspect rear hub nut cotter pin Torque rear hub nut Inspect ale for damage and bends Inspect ale nut torque to 70 ft lb Tape Ale nut Inspect ale nut tape Torque rear brake banjo bolt to 22 ft lb Torque rer caliper to mount bolts to 22 ft lb

4 Inspect rear brake pads for wear Replace rear brake pads Torque Sprocket bolts to 32 ft lb Inspect chain and sprockets for wear Install new sprockets Install prestreched chain Adjust chain tight at its tightest point in the travel Torque swing arm pinch bolts to 22 ft lb Torque rotor bolts to 22 in lb Inspect rotor guard for damage Torque Rotor Guard bolts to 22 ft lb Check ale bearings Replace ale bearings Inspect grab bar for damage Inspect rear fender for damage Torque rear fender mount bolts to 90 in lb Inspect seat latch for wear or damage Replace seat latch Inspect Seat cover Inspect subframe for damage Torque subframe bolts to 40 ft lb Inspect airbo for damage Torque airbo mounting bolts to 90 in lb Spray air filter with Fab 1 Spray inside of airbo with Fab 1 Inspect air filter installation for no air leaks Inspect intake boot and clamps for damage Inspect Carb for fitment to engine and intake tube Verify 4-3/8 inch holes in back of airbo are open Charge Battery Replace Battery Inspect Battery Ground cable for damage Replace Battery Ground Cable Inspect Battery Positive Cable for Damage Replace Battery Positive Cable Inspect Wire Harness for damage Pad Wire Harness at frame locations Replace wire harness Torque and loc tight battery cable to battery connections 50 in lb Torque Upper Shock Bolt 50 ft lb Check rear shock action and inspect for leaks or damage Rebuild rear shock Grease Linkage bearings Repalce linkage bearings Grease Swingarm bearings Replace swingarm bearings

5 Inspect shift lever for damage or wear Replace shift lever Replace shift shaft Inspect rear skid plate for damage Replace rear skid plate Torque and loc tight skid plate bolts 22 ft lb Inspect clutch arm for wear, leaks, or damage Torque Bar clamp bolts to 22 ft lb Check bar mounted controls for damage, wear, and interference Replace bar mounted controls Check kill switch operation Replace kill switch Clean starter button Wire Grips Install new grips Adjust clutch cable Replace clutch cable Check throttle cable Replace throttle cable Check brake fluid level