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Replacing the Spark Plug
Service Interval: Every 400 hours
The spark plug usually lasts a long time; however, the
plug should be removed and checked whenever the engine
malfunctions or every 400 hours. Replace the spark plug
to ensure proper engine performance and reduce exhaust
emission level.
The correct spark plug to use is an NGK-R BKR5E.
The recommended air gap is 0.81 mm (0.032 inch).
1. Clean the area around the spark plug so foreign matter
cannot fall into the cylinder when you remove the
spark plug.
2. Pull wires off of the spark plug and remove the plugs
from the cylinder head.
3. Check the condition of the side electrode, center
electrode, and center electrode insulator to ensure that
there is no damage.
Important: A cracked, fouled, dirty, or otherwise
malfunctioning spark plug must be replaced. Do
not sand blast, scrape, or clean electrodes by using
a wire brush because grit may eventually release
from the plug and fall into the cylinder. The result
is usually a damaged engine.
Figure 43
1. Air gap at 0.81 mm (0.032 inch)
4. Set the air gap one each plug between the center and
side electrodes at 0.81 mm (0.032 inch).
5. Install the correctly gapped spark plug and tighten
them to 24.5 to 29 N-m (18 to 22 ft-lb). If you cannot
use a torque wrench, tighten the plug firmly.
6. Install the spark plug wire.
Fuel System
Maintenance
Replacing the Fuel Filter
Service Interval: Every 400 hours
1. Raise the bed (if so equipped) and place the safety
support on the extended lift cylinder to hold up the
bed.
2. Unplug the wire harness connectors from the fuel
pump (Figure 44).
3. Loosen the hose clamp and disconnect the fuel line
from the fuel pump cap (Figure 44).
1. Fuel pump
2. Hose clamp
4. Un-thread the fuel pump cap from the top of the fuel
tank (Figure 44).
5. Remove the fuel pump assembly and fuel filter from
the tank (Figure 44.
6. Remove the clamp securing the fuel filter hose to the
fuel pump fitting. Remove the hose from the fitting
(Figure 44).
7. Insert the new hose clamp onto the new fuel filter hose.
8. Insert the hose onto the fuel pump and secure the
clamp.
9. Insert the assembly into the fuel tank and tighten the
cap to 20 to 22 N-m (175 to 200 in-lb).
10. Connect the wires and secure the hose with the hose
clamp.
38
Figure 44
3. Fuel line/fuel filter
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