SECOND ECHELON PREVENTIVE MAINTENANCE
Paragraph
Second echelon preventive maintenance services 26
26. SECOND ECHELON PREVENTIVE MAINTENANCE SERVICES.
=a.= Regular scheduled maintenance inspections and services are
a preventive maintenance function of the using arms, and are the
responsibility of commanders of operating organizations.
(1) FREQUENCY. The frequencies of the preventive maintenance services
outlined herein are considered a minimum requirement for normal
operation of vehicles. Under unusual operating conditions such as
extreme temperatures, and dusty or sandy terrain, it may be necessary
to perform certain maintenance services more frequently.
(2) FIRST ECHELON PARTICIPATION. The drivers should accompany their
vehicles and assist the mechanics while periodic second echelon
preventive maintenance services are performed. Ordinarily the driver
should present the vehicle for a scheduled preventive maintenance
service in a reasonably clean condition; that is, it should be dry,
and not caked with mud or grease to such an extent that inspection and
servicing will be seriously hampered. However, the vehicle should not
be washed or wiped thoroughly clean, since certain types of defects,
such as cracks, leaks, and loose or shifted parts or assemblies are
more evident if the surfaces are slightly soiled or dusty.
(3) If instructions other than those contained in the general
procedures in paragraph (4) or the specific procedures in paragraph (5)
which follow, are required for the correct performance of a preventive
maintenance service, or for correction of a deficiency, other sections
of the vehicle operator’s manual pertaining to the item involved, or a
designated individual in authority, should be consulted.
(4) GENERAL PROCEDURES. These general procedures are basic instructions
which are to be followed when performing the services on the items
listed in the specific procedures. The second echelon personnel must
be thoroughly trained in these procedures so that they will apply them
automatically.
(_a_) When new or overhauled subassemblies are installed to correct
deficiencies, care should be taken to see that they are clean,
correctly installed, properly lubricated, and adjusted.
(_b_) When installing new lubricant retainer seals, a coating of the
lubricant should be wiped over the sealing surface of the lip of the
seal.
(_c_) The general inspection of each item applies also to any
supporting member or connection, and usually includes a check to see
whether the item is in good condition, correctly assembled, secure,
or excessively worn. The mechanics must be thoroughly trained in the
following explanations of these terms:
_1._ The inspection for “good condition” is usually an external visual
inspection to determine whether or not the unit is damaged beyond safe
or serviceable limits. The term “good condition” is explained further
by the following: not bent or twisted, not chafed or burned, not broken
or cracked, not bare or frayed, not dented or collapsed, not torn or
cut.
_2._ The inspection of a unit to see that it is “correctly assembled”
is usually an external visual inspection to see whether or not it is in
its normal assembled position in the vehicle.
_3._ The inspection of a unit to determine if it is “secure” is usually
an external visual examination, a hand‐feel, or a pry‐bar check for
looseness; such an inspection should include any brackets, lock
washers, lock nuts, locking wires, or cotter pins used in assembly.
_4._ “Excessively worn” will be understood to mean worn, close to or
beyond serviceable limits, and likely to result in a failure if not
replaced before the next scheduled inspection.
(_d_) Special Services. These are indicated by repeating the item
numbers in the columns which show the interval at which the services
are to be performed, and show that the parts, or assemblies, are to
receive certain mandatory services. For example, an item number in
one or both columns opposite a _Tighten_ procedure, means that the
actual tightening of the object must be performed. The special services
include:
_1. Adjust._ Make all necessary adjustments in accordance with the
pertinent section of the vehicle operator’s manual, special bulletins,
or other current directives.
_2. Clean._ Clean units of the vehicle with dry‐cleaning solvent to
remove excess lubricant, dirt, and other foreign material. After the
parts are cleaned, rinse them in clean dry‐cleaning solvent, and dry
them thoroughly. Take care to keep the parts clean until reassembled,
and be certain to keep dry‐cleaning solvent away from rubber or other
material which it will damage. Clean the protective grease coating from
new parts, since this material is not a good lubricant.
_3. Special lubrication._ This applies both to lubrication operations
that do not appear on the vehicle Lubrication Guide, and to items
that do appear on such guides, but should be performed in connection
with the maintenance operations, if parts have to be disassembled for
inspection or service.
_4. Serve._ This usually consists of performing special operations,
such as replenishing battery water, and draining and refilling units
with oil.
_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
[Sidenote: 1000 Mile Maintenance]
NOTE: If tactical situation does not permit a full road test, perform
items 2, 3, 4, 5, 6, 7, 8, 9, 12, and 14, which require slight or no
movement of the vehicle. When a road test is possible, it should be for
preferably 5, and not over 10 miles.
[Sidenote: 1]
=Before‐operation Inspection.= Perform Before‐operation Service listed
on W.D. Form No. 418. “Driver’s Trip Ticket and Preventive Maintenance
Service Record” (described in par. 15), to determine if vehicle is in a
satisfactory condition to make the road test safely.
[Sidenote: 2]
=Ease of Starting.= Start engine and observe action of starter. Note if
engine responds readily.
[Sidenote: 3]
=Oil Circulation.= Oil circulation is normally indicated by oil signal
light (red light) in instrument panel being out. When red light is on,
oil is not circulating. Observe for excess smoke in exhaust. CAUTION:
_If red light fails to go out after engine has been started, stop
engine at once. Refer to paragraph 30 for possible causes._
[Sidenote: 4]
=Instruments.= Observe instruments for proper or normal indication and
functioning of system to which they apply.
SPEEDOMETER AND ODOMETER. Speedometer must indicate vehicle speed
without excessive noise or fluctuation; odometer must record 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, the red light should go on, indicating no
oil circulation. When engine is started, light should go out.
GENERATOR SIGNAL LIGHT. With switch on, and before starting engine,
the green signal light should go on, indicating discharge of battery.
After starting engine, increase engine speed to a medium fast idle;
green signal light should then go out, indicating generator is charging
battery. CAUTION: _Continue observation of signal lights during road
test, and if lights should fail to operate as indicated above, stop
engine, investigate cause, and correct or report trouble to proper
authority._
[Sidenote: 5]
=Brake Operation.= Test foot brake for safe stop within reasonable
distance. Note squeaks or chatter that might indicate wet, oily,
dirty, or loose lining, damaged drum, or improper adjustment. Apply
hand‐operated front brake only in conjunction with rear brake and
observe whether it operates effectively in assisting to make a quicker
stop.
[Sidenote: 6]
=Clutch Operation.= Before moving vehicle, make sure that clutch pedal
has satisfactory free travel before it begins to disengage clutch; that
it releases clutch completely before reaching end of travel; and that
there are no unusual noises in clutch‐release mechanism. When starting
vehicle, observe whether clutch grabs, chatters, or slips when fully
engaged.
[Sidenote: 7]
=Gearshift.= Shift through entire gear range of transmission and
observe whether mechanism operates freely without clashing or jumping
out of gear. Note any unusual vibration that might indicate loose
engine or transmission mountings.
[Sidenote: 8]
=Unusual Noises.= During entire road test, listen for unusual noises
that might indicate worn, loose, damaged, or insufficiently lubricated
parts in the entire motorcycle, particularly in engine and accessories,
or in the power train.
CAUTION: _Loose primary (front) drive chain, with slack in excess of
1/2 inch total up‐and‐down motion, can cause excessive noise which
sounds like engine knock. Remove inspection cover for examination of
chain._
[Sidenote: 9]
=Steering.= Observe steering mechanism for indication of looseness
or excessive binding through full turning range. With hands resting
lightly on handle bars and vehicle in vertical position, observe
whether there is any tendency to pull to one side when operating at a
reasonable speed. Note any indication of steering instability at higher
speeds.
[Sidenote: 10]
=Balance.= If vehicle does not balance properly in operation, inspect
for misalinement of rear wheel.
[Sidenote: 11]
=Speedometer and Odometer.= Inspect speedometer for proper operation,
excessive fluctuation, or unusual noise. Observe odometer for correct
recording of trip and total mileage.
[Sidenote: 12]
=Throttle and Spark Controls.= Set throttle stop screw and low speed
needle adjustment so that engine will operate smoothly and will not
stall at idling speed. With vehicle running at a speed of 30 miles per
hour, or faster, in high gear, turn throttle control grip to “OPEN”
and “CLOSED” positions and note whether engine responds instantly to
throttle changes. Turn spark control grip and note whether it fully
advances and retards ignition timer.
[Sidenote: 13]
=Power and Operation.= Observe engine for normal pulling power, and
good operating characteristics in each speed, from first to high gear.
Also observe whether engine misses, stalls, knocks excessively, or
makes any other unusual noise.
[Sidenote: 14]
=Carburetor Adjustment.= No carburetor adjustment, other than idle
adjustment as performed in item 12, is required on this vehicle.
[Sidenote: 15]
=Brake Drum and Hub Temperature.= Immediately after completing road
test, feel front and rear brake drums and wheel hubs for overheating.
[Sidenote: 16]
=Power Train Temperatures.= Feel transmission for overheating.
MAINTENANCE OPERATION
[Sidenote: 17]
=Compression Test.= With throttle wide‐open, test compression with
starter. If engine lacks compression, inspect for leaks.
[Sidenote: 18]
=Transmission.= Inspect transmission for good condition, secure
mounting, and leaks. Inspect oil level. Drain and refill transmission
to level of transmission filler plug opening with specified grade of
engine oil. CAUTION: _Always drain transmission immediately after it
has been warmed and agitated by operation of engine. Refill as soon as
draining is completed to avoid hazard of operating without lubricant.
Tighten all mounting and assembly bolts securely._
[Sidenote: 20]
=Engine Oil.= Inspect oil tank for oil level: drain and refill tank.
CAUTION: _Fill to within 1 inch of filler opening and filler cap
with specified weight of oil. Always drain immediately after engine
operation and refill as soon as draining is completed, to avoid hazard
of operating without lubricant._
[Sidenote: 21]
=Battery and Carrier.= Clean top of battery. See that battery and
carrier are in good condition, and that carrier is securely mounted.
Remove cell caps: make sure that vents are open. Test specific gravity
with hydrometer and record readings on work sheet, W.D. AGO Form No.
463. Readings below 1.225 indicate need for recharge, or battery
failure. Variation between cells of more then 0.025 must be reported.
Read and record voltage of battery (6‐volt reading is normal). Bring
electrolyte to 5/16 inch above tops of plates, using clean, drinkable
water. If excessive looseness of battery in case is noted, check for
presence of rubber pad in bottom of case, and make sure rubber pad is
installed on top of battery, when battery service is completed.
[Sidenote: 22]
=Battery Wires and Terminals.= Inspect battery for good condition and
secure connections. Look for worn spots in wire insulation. Oil the
felt washers on battery terminals.
[Sidenote: 23]
=Electrical Wiring.= Inspect all electric wiring to see that it is in
good condition, securely attached, and connected. Look for worn spots
in insulation.
[Sidenote: 24]
=Generator Drive and Mounting, and Relay.= Inspect generator for 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 must be cleaned with No. 00 sandpaper.
Blow out with compressed air. If commutator is in bad condition or
excessively worn, replace generator. Remove relay cover, being careful
to avoid damage to mechanism, and inspect for cleanliness. Blow out
with air if wet or dirty. CAUTION: _Do not attempt to adjust relay, or
to clean it in any other manner._
[Sidenote: 25]
=Timer= (=Circuit Breaker=). Clean and remove timer cover. See that
wiring leads are securely connected and that inside of the timer is
clean. Inspect breaker points to see that they are clean, well‐lined,
engaging squarely, and are not excessively pitted, burned, or worn.
See that condenser mounting screw is tight. Breaker lever should be
free on its pivot and well insulated from the pivot pin. Determine if
breaker arm spring exerts normal force against arm. Examine camshaft
by hand‐feel to see whether it is excessively worn in its bushings; if
camshaft bushings are worn excessively, install new timer. If points
are slightly burned or pitted, dress them with a fine file. If breaker
points are unserviceable, install a new set, taking care to aline them
and to adjust gap to 0.022 inch. Apply one drop of oil to breaker arm
pivot pin. Use clean cloth to wipe cam and then coat with a very light
film of light grease. CAUTION: _Be careful to avoid getting oil or
grease on breaker points._
[Sidenote: 26]
=Spark Plugs.= Remove spark plugs, clean with sandblast cleaner, and
inspect for cracked insulators: inspect electrodes for good condition
and adjust gap to 0.025 to 0.030 inch; replace faulty plugs. Be sure
to install new gasket with new plug. Inspect radio suppressors on plug
cables for good condition and secure attachment.
[Sidenote: 27]
=Ignition and Light Switch.= Make sure that the switch is in good
condition and operating properly in all positions.
[Sidenote: 28]
=Lights, Service and Blackout.= See that all lights are clean, in good
condition, properly aimed, and securely mounted. Tactical situation
permitting, turn switch to each of its positions and observe whether
service and blackout lights operate properly, and whether they go out
when switched off. Operate dimmer switch on left handle bar to see
whether it depresses beam of service headlight. Apply foot brake for
check of both blackout and service stop light operation. Inspect lenses
for breakage, and headlight reflector for discoloration. Clean all
lenses.
[Sidenote: 29]
=Horn.= Tactical situation permitting, sound horn to test for normal
signal. Examine horn for good condition, secure mounting, and tight
wiring connections.
[Sidenote: 30]
=Cylinder Heads.= If cylinder head gaskets show signs of leakage,
tighten head bolts: if leakage persists, new gaskets should be
installed. A head bolt wrench (Fed‐Stock No. 41-W-1525) is available
with which head bolts can be tightened without removing tanks for
wrench clearance. If tanks are removed to permit taking off heads and
installing new gaskets, bolts should then be tightened evenly with a
torque wrench to a tension of 60 foot‐pounds minimum, or 65 foot‐pounds
maximum, when engine is cold.
[Sidenote: 31]
=Cylinder Hold‐down Nuts.= If these nuts are loose, or there is
excessive oil leakage around cylinder bases, tighten nuts evenly when
engine is cold. If excessive leakage persists, new gaskets should be
installed. CAUTION: _If cylinder base nuts are loose, perform item 36
before starting engine._
[Sidenote: 32]
=Engine Mountings.= Inspect top engine mounting bracket and bolt for
good condition and security. CAUTION: _Tight seating of the engine
bracket mounting bolt is a necessity for effective radio bonding.
Inspect four lower engine mounting bolts for signs of looseness.
Tighten as required._
[Sidenote: 33]
=Engine Crankcase.= Examine engine crankcase for good condition and for
leaks. Make sure timing gear cover screws, and oil feed and scavenger
pump nuts, are tight.
[Sidenote: 34]
=Intake Manifold.= Examine manifold for good condition and secure
mounting. Make sure manifold nuts are tight.
[Sidenote: 35]
=Muffler and Exhaust Pipes.= Inspect muffler and exhaust pipes for good
condition, secure mounting, and for leaks. Be sure tail pipe opening is
not restricted.
[Sidenote: 36]
=Valve Mechanism.= When engine is cold, adjust valve tappet clearance
to 0.004-inch minimum, 0.005-inch maximum on intake valve; 0.006-inch
minimum, 0.007-inch maximum on exhaust valve. See that valve springs
are in good condition and properly secured; that valve tappet adjusting
screws and lock nuts are in good condition; and that valve covers are
in good condition, secure, and not leaking oil.
[Sidenote: 37]
=Starter.= Examine pedal, crank, and return spring for good condition,
correct assembly, and secure mounting. Starter should operate without
binding, and return spring should bring starter crank to its disengaged
position when foot pressure is removed. CAUTION: _Make sure that
starter crank pinch bolt is installed with head of bolt toward rear of
vehicle when crank is in upright position._
[Sidenote: 38]
=Engine Cooling Fins.= Inspect engine cooling fins for good condition
and cleanliness. Remove all dirt or foreign matter. Do not apply paint
to cooling fins.
[Sidenote: 39]
=Filler Caps and Vents.= Wipe dirt and dust from filler caps of fuel
and oil tanks. Inspect caps and gaskets to see that they are in good
condition. Note whether vent in fuel filler cap is open. Reinstall
caps, observing that each locks properly on filler neck. Do not
interchange fuel and oil tank filler caps.
[Sidenote: 40]
=Fuel Tank Valves and Lines.= See that valves and lines are in good
condition, secure, and not leaking. Test fuel shut‐off valve for ample
friction to hold valve in reserve position. See that valve lifts freely
enough to operate satisfactorily.
[Sidenote: 41]
=Oil System Leaks.= Examine oil tank, oil lines, vent line, and
connections for good condition, secure attachment, and for leaks.
[Sidenote: 42]
=Carburetor and Fuel Filter= (=Gasoline Strainer=). Examine carburetor
and fuel filter for good condition, secure connections, and for leaks.
Shut off fuel tank valve and remove filter (strainer) cap and screen.
Wash cap and screen in dry‐cleaning solvent, and open shut‐off valve
slightly to flush filter body. Reassemble screen, gaskets, and cap,
being careful not to damage gaskets. Use new gaskets if necessary.
Drain water and foreign matter from carburetor bowl by removing bowl
drain plug. Open shut‐off valve slightly to flush carburetor bowl while
plug is out. Replace plug, being careful to avoid crossing threads.
Open fuel tank shut‐off valve and check for leaks.
[Sidenote: 43]
=Air Cleaner.= Remove oil cup; inspect condition of oil, and amount of
sediment. If service is required, remove filter elements, clean and
fill cup to NORMAL level. Wash elements in dry‐cleaning solvent, dry
thoroughly with compressed air, immerse each element in oil in cup, and
reassemble elements and oil cup to air cleaner body 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 wash element._
[Sidenote: 44]
=Gearshift Lever and Linkage.= See that gearshift lever and linkage
are in good condition, secure, and not excessively worn. Lubricate
all joints with a few drops of engine oil. Adjust shifter lever so
that when moved to any gear position in shifter guide on tank, the
transmission is shifted to full engagement in corresponding gear.
[Sidenote: 45]
=Primary Drive.= Remove inspection hole cover from front chain guard.
With clutch engaged and transmission in neutral, rotate primary chain
to position of least slack. Check chain for 1/2-inch deflection.
Deflection measurement should be total up‐and‐down free movement.
Inspect chain for adequate lubrication. Loosen front and rear chain
oiler adjusting screws two turns each. Do not remove screws. Idle
engine 1 minute, then tighten screws firmly, but do not force. This
operation serves to flush control valves and rear chain oiler pipe.
[Sidenote: 46]
=Clutch Pedal and Linkage.= Inspect clutch pedal clevis connections and
cable to see that they are in good condition and not excessively worn.
Check free travel of clutch pedal to make sure it is within specified
limits. With foot pedal in fully disengaged position (heel against
footboard) clutch release lever must clear sprocket cover stud and nut
by about 1/16 inch: with foot pedal in fully engaged position, clutch
release lever must have between 1/8- and 1/4-inch of free movement
on end of foot pedal cable. Lubricate all joints with a few drops of
engine oil, including cable at each end of cable housing.
[Sidenote: 47]
=Rear Chain and Guard.= Inspect rear chain guard for good condition
and secure mounting. Remove chain, wash thoroughly in dry‐cleaning
solvent, and hang it up to dry. See that chain is in good condition,
not excessively worn, and has no broken rollers on side plates. Soak
chain in SAE 10 engine oil for a short period of time to allow oil
to penetrate into all rollers; drain chain, and wipe off excess oil.
Inspect countershaft sprocket, and rear wheel sprocket to see that they
are in good condition, not excessively worn, and that rear sprocket
rivets are tight. Do not reinstall chain until item 71 has been
performed. When reinstalling chain, make sure that connecting link is
in good condition and securely locked. See that open end of connecting
link spring clip is trailing in direction of chain travel. Adjust chain
(paragraph 60).
[Sidenote: 48]
=Final Drive Sprockets.= Inspection of final drive sprockets is made
when performing item 47.
[Sidenote: 50]
=Paint and Markings.= Examine vehicle for good condition and see that
paint is not rubbed to a polish, and has no bare spots that might rust
or reflect light. See that vehicle markings are legible.
[Sidenote: 51]
=Frame.= Examine frame for good condition; observe whether it seems to
be sprung out of alinement.
[Sidenote: 52]
=Steering Head and Fork Stem.= Raise front end of vehicle by placing
blocks under skid plate. Complete all following items to and including
item 71, before lowering vehicle to ground. Examine steering head and
fork stems for good condition. Note whether there is up‐and‐down play
caused by loose bearings. Move handle bars through complete range
and observe if there is any binding which might indicate improperly
adjusted or defective bearings.
[Sidenote: 53]
=Handle Bars.= Examine handle bars for good condition and secure
mounting.
[Sidenote: 54]
=Throttle Control.= See that grip is in good condition, that throttle
opens and closes completely as grip is turned to its extreme positions,
and that control wire and housing are in good condition and secure.
Lubricate lightly through hole in rear of grip to avoid rusting and
“freezing.” If grip does not rotate freely, disassemble grip, clean,
and lubricate spiral control parts.
[Sidenote: 55]
=Spark Control.= See that grip is in good condition, that spark is
fully advanced and retarded as the grip is turned to its extreme
positions; that the control wire and housing are in good condition and
secure. Lubricate lightly through hole in rear of grip to avoid rusting
and “freezing.” If grip does not rotate freely, disassemble grip,
clean, and lubricate spiral control parts.
[Sidenote: 57]
=Rear View Mirror.= Clean rear view mirror and examine for good
condition and secure mounting.
[Sidenote: 58]
=Front Fender= (=Mudguard=). Examine front fender for good condition
and secure mounting; see that fender does not scrape tire.
[Sidenote: 59]
=Weapon Carrier.= Inspect weapon carrier for good condition and secure
mounting.
[Sidenote: 60]
=Ammunition Box.= See that ammunition box and cover are in good
condition and securely attached.
[Sidenote: 61]
=Front Springs.= See that front springs and their mountings are in good
condition, correctly assembled, and secure.
[Sidenote: 62]
=Front Forks.= See that front forks are in good condition and securely
mounted.
[Sidenote: 63]
=Front Fork Rocker Plates (Rocker Arms).= See that front fork rocket
plates are in good condition, secure, and not excessively worn. Tighten
rocker plate stud nuts securely.
[Sidenote: 64]
=Front Fork Damper.= Inspect steering damper for good condition and to
see that it operates freely. Observe whether friction disks are glazed,
coated with grease, or excessively worn.
[Sidenote: 65]
=Front Brake and Control Linkage.= See that control linkage operates
freely, that all connections are tight, and that brake is adjusted so
that end of hand lever has 1/4 free travel before meeting resistance.
Look for any indications of a cracked or excessively worn brake drum:
badly worn, loose, or grease‐saturated linings. If there are any
such indications, remove wheel for closer inspection. Look for badly
worn brake side cover bushing, shackle bushings and studs, or brake
operating stud bearing. Apply a few drops of engine oil to control
cable, especially at control housing oiler at left handle bar, and to
pin joints.
[Sidenote: 66]
=Front Wheel Alinement and Spokes.= Examine front wheel spokes for
presence, good condition, and tightness. If loose spokes are found,
tighten evenly, taking care not to distort rim out‐of‐round, or to
cause run‐out. Examine rim for good condition, and spin wheel to see
that it has no appreciable run‐out.
[Sidenote: 67]
=Front Wheel Bearings.= Inspect wheel to see whether bearings are
excessively loose. Wheel should have slight amount of side play at
rim. Spin wheel and listen for unusual noises which might indicate dry
or defective bearings or races. Observe for excessive grease leak.
If wheel is found to need only slight cone readjustment to correct
excessive bearing play, remove wheel and make this adjustment (par.
126). If indications are found that hub is otherwise in bad order,
replace wheel.
EACH SIXTH 1,000-MILE MAINTENANCE SERVICE. Remove front wheel, axle
sleeve and bearing, and, together with wheel hub, clean thoroughly in
dry‐cleaning solvent. Inspect parts for good condition: inspect brake
drum. Inspect lining for good condition and secure attachment, and see
that it is neither excessively worn nor soaked with grease. Repack
bearings, hub, and axle sleeve with specified lubricant. CAUTION: _Make
sure that hands and grease are perfectly clean, and that grease is
forced between balls onto the cone._ Reassemble and adjust bearings
according to instructions in paragraph 126, taking care to see that
wheel is properly alined. If unusual operating conditions, such as
fording streams, have indicated probable contamination of lubricant,
this service should be performed more frequently.
[Sidenote: 68]
=Front Wheel Axle Nuts.= Tighten axle nuts, making sure that cotter
pins are installed. Slot in stabilizer plate must be anchored on
extended end of left‐front rocker plate stud.
[Sidenote: 69]
=Tires, Front and Rear.= Gage tires and inflate to 18 pounds front, and
20 pounds rear (cold). Make sure that valve stems are in good condition
and correctly installed, and that valve caps are present and secure.
Examine tires for cuts, bruises, breaks, and blisters: remove imbedded
glass, nails, or other foreign matter from tire treads; observe treads
for excessive or irregular tire wear. At any inspection when unusual or
irregular tire wear becomes evident, interchange front and rear tires.
[Sidenote: 70]
=Rear Wheel Alinement and Spokes.= With vehicle on rear stand, inspect
in same manner as front wheel (item 66). If it is necessary to aline
wheel in frame, make sure sprockets and chains are in correct alinement.
[Sidenote: 71]
=Rear Wheel Bearings and Seals.= Inspect wheel to see whether bearings
are excessively loose (wheel should have a slight amount of play at
rim). Spin wheel and listen for unusual noise which might indicate
dry or defective bearings. Also observe whether there is excessive
grease leak. Test for excessive end play. If wheel is found to have
considerable side play at rim, indicating excessively worn bearings, or
there is evidence of hub assembly being in bad order otherwise, replace
wheel. If wheel must be replaced, inspect brake drum and lining for
good condition, as indicated in item 75, before reinstalling wheel.
CAUTION: _Make sure that wheel mounting socket screws are tight._
[Sidenote: 72]
=Rear Wheel Axle Nut.= See that rear wheel axle nut is in good
condition and securely tightened.
[Sidenote: 74]
=Rear Fender= (=Mudguard=). Inspect rear fender for good condition and
secure attachment.
[Sidenote: 75]
=Rear Brake and Control Linkage.= See that brake control linkage
operates freely, and that all connections are secure. Look for
indications of badly worn or grease‐saturated linings. If brake
operating lever stands considerably ahead of vertical, excessive lining
wear is indicated. If grease has worked out between brake drum and
brake cover, grease‐saturated linings are indicated. In either case
the wheel should be removed for closer inspection. Inspect drum for
cracks or excessive wear. Make sure wheel mounting socket screws are
tight. Examine linkage for loose or worn pin or clevis, and for missing
washers or cotter pins. Apply a few drops of engine oil to all linkage
joints. Brake pedal should have 1-inch free travel before brake begins
to meet resistance. Adjust length of brake rod at brake operating lever
to provide 1-inch free pedal travel.
[Sidenote: 77]
=Footboard and Rest.= Examine footboard and rest for good condition and
secure attachment.
[Sidenote: 78]
=Saddle Spring and Hinge.= Examine saddle for good condition and secure
mounting, paying particular attention to torn leather, ripped seams,
sagging or broken spring in seat post, and excessive wear in front
hinge. CAUTION: _Make sure that spring wire clip properly locks the
saddle rear hinge clevis pin._
[Sidenote: 79]
=Luggage Carrier.= Examine luggage carrier for good condition and
secure mounting.
[Sidenote: 80]
=Saddle Bags.= Examine saddle bags for good condition, cleanliness, and
secure fastening to luggage carrier. Note particularly whether leather
is torn, seams ripped, or straps and buckles missing or damaged.
[Sidenote: 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 is securely clamped to
motorcycle frame. Check all items with stowage list (pars. 21, 22 and
23). Make sure that vehicle manuals and Accident Report Form No. 26 are
present on vehicle and legible.
[Sidenote: 82]
=Safety Guards.= Inspect safety guards for good condition and secure
mounting.
[Sidenote: 83]
=Leg Shields.= Inspect leg shields for good condition and secure
mounting. NOTE: _Motorcycles operating in warm weather should not be
equipped with leg shields, as they seriously hamper engine cooling._
[Sidenote: 84]
=Skid Plate.= Examine skid plate for good condition and secure
mounting. CAUTION: _Skid plate must be present._
[Sidenote: 85]
=Vehicle Lubrication.= Lubricate all points of vehicle in accordance
with instructions in this manual, Lubrication Guide, current
lubrication bulletins or directives, and the following instructions:
Any unit that required disassembly for inspection purposes must be
lubricated correctly unless the vehicle is to be deadlined for the
repair of that unit. Use only clean lubricant. Keep all lubricant
containers covered except when used during lubrication. Before applying
lubricant, always wipe dirt from the lubrication fitting or plug so
that dirt will not enter with the lubricant. If lubricant fittings or
plugs are missing or damaged, replace them. Clean the hole in which the
fitting is to be installed, and lubricate 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, lubricate
sparingly the front wheel hub, rear wheel hub, front brake side cover
bushing, front brake operating lever stud, and rear brake operating
lever stud, to prevent grease reaching brake linings. Rider should
be advised whenever wheel bearings are serviced or adjusted, so that
during the next road operation he may determine whether bearings or
brake drums are running hot, due to overtight adjustment of bearings,
or a dragging brake.
Do not apply more than specified amount of lubricant to generator or
timer (circuit breaker). To do so may cause failure of the unit.
Wipe off excess applied lubricant that may drip onto brake or operating
surfaces, soil clothes, or detract from vehicle’s appearance.
Parts or assemblies that have already been lubricated while
disassembled for inspection, gear cases that have been drained and
refilled as mandatory items in the procedure, and those parts that
have been indicated for special lubrication, will be omitted from the
general lubrication of the vehicle.
[Sidenote: 86]
=Final Road Test.= Make a final road test, reinspecting items 2 to 16,
inclusive. Be sure to recheck transmission to see that lubricant is at
correct level and not leaking. Confine this road test to the minimum
distance necessary to make satisfactory observation. Correct or report
all deficiencies found during final road test to designated authority.