Westward THE INTERCEPTOR BT-57 Install guide

WESTWARD
INDUSTRIES LTD
liTHE INTERCEPTOR''
2501 Hwy 1A West
Portage Ia Prairie, MB
CANADA R1N 3L5
SHOP MANUAL
PART NO. 938000

Westward Industries Umited, G0-4 Interceptor Service Manual
INTRODUCTION
Important Safety Notice
Good service methods and correct repair
procedures are important for the safe, reliable
operation
of the G0-4 Interceptor vehicle as well
as the personal safety of the person doing the
work. This SERVICE MANUAL provides general
directions
for doing service and repair work with
tested, effective techniques. By following them
it will assure reliability.
There are
many variations in procedures,
techniques and tools, and parts for servicing
vehicles, as well as in the skills of the person
doing
the work. The Service Manual cannot
possibly use all these variations and provide
advice
or cautions for each procedure or
operation. Thus anyone who departs from the
instructions provided in this manual must first
establish that he compromises neither his
personal
safety nor the vehicle integrity by his
choice
of methods, tools or parts.
Notes, Cautions, and Warnings
As you read these procedures, you will come
across NOTES, CAUTIONS, and WARNINGS.
NOTES give
you added information that will help
to complete a particular procedure. CAUTIONS
are given to prevent you from making an error
that could damage a vehicle. WARNINGS
remind
you to be very careful in those areas
where carelessness can cause personal injury.
The
following general WARNINGS should be
followed when you work on a vehicle.
•
Always wear safety glasses for eye
protection.
• Do not smoke when working on a vehicle.
• Remove rings,
watches, loose hanging
jewelry and loose clothing before beginning
to work on a vehicle.
• Use
safety stands whenever a procedure
requires
you to be under the vehicle.
•
Be sure the ignition switch is in the OFF,
unless
otherwise required by the procedure.
• Set the park brake when working on the
vehicle. Set the automatic transmission in
PARK unless
instructed otherwise for a
specific operation. Place
wood blocks (4" x
4" or larger) against the front and rear
surfaces of the tires to provide further
restraint from inadvertent vehicle
movement.
• Operate the engine in a well-ventilated area
to avoid the danger of carbon monoxide.
• Keep
yourself and your clothing away from
moving parts (e.g. drive belts) when the
engine is running.
• Avoid
contact with hot metal parts such as
radiator,
exhaust, manifold, tail pipe,
catalytic
converter and muffler.
• If it is necessary to work under the engine
compartment, keep hands and other objects
clear of the radiator fan blades! The G0-4 is
equipped
with a cooling fan that may turn
on, even though the ignition switch is in the
OFF position. Disconnect the radiator
electric
motor when working around the
engine when engine is not running.
1

Westward Industries Umited, G0-4 Interceptor Service Manual
What Subjects Are Covered In This Manual?
The
G0-4 Service Manual covers normal service repairs and maintenance for vehicles sold in the United States.
How Is This Manual Organized?
This manual is organized by Section Sub-section and
Page
Section -This covers a specific portion of the vehicle. The first set of numbers on each page indicate the
Group.
Note: A Section usually contains more than one group.
The Sections found
in this service manual are:
2
1 -Vehicle Identification/General Information
2 - Maintenance and Lubrication
3 - Wheels and Tires
4 - Brake System
5- Steering
6 - Suspension
7 -
Axles and Driveshafts
8 -
Automatic Transaxle
9 - Emission Control Systems
10 - Noise, Vibration and Harshness
11 -Engine
12 -Ignition System
13 -Fuel System
14 -Exhaust System
15 -Cooling System
16 - Starting System
17 - Battery and Charging System
18 -Lighting Systems
19 -Instruments, Clusters, Controls and Warning Systems
20 -Wiring Harness, Connectors and Circuit Protection System
21 -Auxiliary Equipment
22 -Heating and Air Conditioning
23 -Seat and Seat Belts
24 - Window Glass, Fixed Glass and Mirrors
25 -Headliner and Flooring
26 -Cargo Box

Westward Industries Limited, G0-4 Interceptor Service Manual
27 -Body Shell/Frame
28 -Exterior Finishes
Sub-section
-each Sub-section covers a component or system. The headings on top of each page indicate the
Section
it is in.
Page -
this set of numbers is indicated in each Section.
How Do You Find the Material in the Service Manual?
1. Locate the Section in the Table of Contents. If you are not sure which Section contains the
information you need, refer to the index located in the back of this manual.
2. Locate the Section number by using the index located at the beginning of each Section.
How Do You Use Each Section?
Each Section has a standard organization that consists of the following information:
Description and
Operation- describes how the component or system works.
Diagnosis and Testing- shows how to pinpoint problems.
Removal and
Installation- how to remove and reinstall components or systems.
Disassembly and Assembly - how to take apart the part or system and put it back together.
Adjustments- how to perform in-vehicle adjustments.
Specifications -provides a summary
of all specifications used in the Section.
Service
Tools/Equipment- lists all the Service Tools used in the Section. Additional headings such as Service
Procedures and Cleaning and Inspection
may be used.
What to Do If You Discover an Error?
Please
let us know if you discover a questionable procedure OR if you have any suggestions for improving this
manual. Your feedback is very important to improving our technical publications. You will get a response to
your questions and suggestions. If necessary, a revision will be issued.
NOTE: The description and specifications contained in this manual were in effect at the time this manual was
approved for printing. Westward Industries reserves the right to discontinue models at any time, or changing
specifications
or design without notice and without incurring any obligation.
3

Westward lndustriefi limited, G0-4 Interceptor Service M:mnal
4

Westward Industries limited, G0-4 Interceptor Service Manual
TABLE OF CONTENTS
SECTION PAGE
Introduction
.................................................................................... 1
1 - Vehicle ldentification/Generallnformation
.................................... 1-1
2- Maintenance and Lubrication ...................................................... 2-1
3 - Wheels and Tires
...................................................................... 3-1
4- Brake System .......................................................................... 4-1
5- Steering ............................. , ..................................................... 5-1
6- Suspension ............................................................................... 6-1
7 - Axles and Drives
hafts ............................................................... 7-1
8- Automatic Transaxle ................................................................. 8-1
9 - Emission Control System
.......................................................... 9-1
10 - Noise, Vibration and Harshness
.................................................. 10-1
11 -Engine ...................................................................................... 11-1
12- Ignition System ......................................................................... 12-1
13 -Fuel System ............................................................................. 13-1
14 -Exhaust System ........................................................................ 14-1
15 - Cooling
System ........................................................................ 15-1
16 -Starting System ........................................................................ 16-1
17 -Battery and Charging System ..................................................... 17-1
18- Lighting Systems ...................................................................... 18-1
19 -Instruments, Clusters, Controls and Warning Systems ..................19-1
20 -Wiring Harness, Connectors and Circuit Protection System ...........20-1
21 -Auxiliary Equipment
.................................................................. 21 -1
22 -Heating and Air Conditioning ...................................................... 22-1
23 -Seat and Seat Belts ................................................................... 23-1
24- Doors, Window Glass, Fixed Glass and Mirrors ............................ 24-1
25 -Headliner and Flooring ............................................................... 25-1
26 -Cargo Box ................................................................................ 26-1
27- Body Sheii/Frame ...................................................................... 27-1
28 -Exterior Finishes ....................................................................... 28-1
5

Section 1 -Vehicle Identification/General Information
SECTION 1 - Vehicle
Identification/General Information
SUBJECT
DESCRIPTION
PAGE
Engine Model
and Serial Number .................. 1-1
Vehicle Certification ................................... 1-1
Vehicle Emission Control Information ............ 1-1
Vehicle Identification Number ...................... 1-1
DESCRIPTION
Vehicle Certification Label
The plate is located on
the front left-hand side of
the dash.
The upper
half of the label contains the name of
the manufacturer, month and year of
manufacture, Gross Vehicle Weight Rating
(GVWR), and Gross Axle Weight Rating (GAWR).
The Vehicle
Certification Label also contains a 17
character Vehicle Identification Number (VIN).
Vehicle
Identification Number
The official Vehicle Identification Number (VIN)
for title and registration is stamped on a decal.
Use
this number for warranty identification of the
vehicle: it indicates manufacturer, body type,
engine, model and product serial number.
The last three (3)
digits of the Vehicle
Identification Number indicates the serial number
of the unit.
Engine Model and Serial
Number
It is located just below the oil filler cap of the
engine.
Vehicle Emission
Control Information
It is located on the engine electrical rail above the
coolant recovery bottle.
SUBJECT PAGE
GENERAL INFORMATION
Preparing
of Tools/Equipment ...................... 1-2
Reassembly
............................................ 1-2
Towing
.................................................. 1-3
Measuring Units
and Terms ...................... 1-3
Vehicle Certification Label/Vehicle Identification Number
Engine
Model and Serial Number/Vehicle Emission Control
Information Decal
1-1

GENERAL INFORMATION
Preparing of Tools and Measuring Equipment
Make sure that all necessary tools and measuring
equipment are available before
starting work.
Special Tools- use when they are required.
Removal of Parts - while correcting a problem, try
to determine the cause. Begin work only after
first learning which parts and subassemblies must
be removed and disassembled for replacement or
repair.
Disassembly -
if the disassembly procedure is
complex, requiring
many parts to be
disassembled, all parts should be disassembled in
a
way that will not affect their performance or
external appearance and can be identified so that
reassembly can be performed efficiently.
1. Inspection of parts. Each part, when
removed, should be carefully inspected for
malfunctioning, deformation, damage or
other problems.
2. Arrangement of parts -all disassembled
parts should be carefully arranged
for
reassembly. Keep new and reused parts
separate so
that they will be easy to identify
and replace.
3. Cleaning parts for reuse -parts that are to
be reused should be carefully and thoroughly
cleaned by the appropriate method.
Reassembly
Standard values, such as torques and certain
adjustments,
must be strictly observed in the
reassembly of parts.
If removed, these parts should be replaced with
new ones.
1. Oil Seals
2. Gaskets
3.
0-rings
4. Lockwashers
5. Cotterpins (lock pins)
6.
Nylon nuts
1-2
Depending on where they are:
1. Sealant should be applied to gaskets.
2. Oil should
be applied to moving
components of parts.
3. Specified oil
or grease should be applied
at the prescribed locations (e.g. oil
seals, etc.) before the assembly.
Adjustments
• Use gauges and testers to make adjustments
to standard values.
Electrical
System
• Be sure to disconnect the battery cable from
the negative (-) terminal to battery.
• Never pull on the wiring when disconnecting
connectors.
• Locking connectors must be heard to click for
the connector to be secure.
• Handle sensors and relays carefully.
Be
careful not to drop them or hit them against
parts.
Rubber Parts and Tubing - always prevent
gasoline
or oil from touching rubber parts or
tubing.
Jack and Safety Stand Rigid Rack) Positions
Front - Jack Position: place under the center of
the front frame.

Section 1- Vehicle Identification/General Information
Safety Stand Positions -place on the side of tube
guard frame.
Rear- Jack Position: Place at the back of the
tube guard frame under trailing arm.
Safety stand positions -place on tube guard
frame
at front of frame and near bumper.
Towing
Proper towing equipment is necessary to prevent
damage
to the vehicle during any towing
operation. Laws and regulations applicable to
vehicles in tow must be observed.
CAUTION: Tow this vehicle from the front with
the rear wheel on dollies.
Towing vehicle when stuck
CAUTION:
a) The power assistance segment of the brakes
will be inoperable when the engine is off.
b) When using either tow hooks or chains,
always pull cable or chain straight away
from the hook and do not apply any
sideways force to it. To further help prevent
damage, do not take up slack too quickly in
the cable or chain.
c) Rear
towing should be used only in
emergency situations (e.g. to pull the vehicle
from a ditch, a snowbank or mud).
WARNING: PLEASE
MAKE SURE THE
TRANSMISSION IS IN
"N" (Neutral) AND
EMERGENCY BRAKE IS OFF. FAILURE TO DO SO
CAN CAUSE SEVERE DAMAGE TO THE
TRANSMISSION.
Units
ft-lb (N-m, m-Kg) ................................... Torque
rpm
.............................. Revolutions per minute
A
..................................................... Amperes
V ........................................................ Volt(s)
W ........................................ ohm(s)(resistance)
psi (kPa, kg/cm2) ....... pressure (usually positive)
in Hg (mm Hg)
.......... pressure (usually negative)
W
........................................................... Watt
Abbreviations used in manual
ABDC ........................ After bottom dead center
ACC
............................................. Accessories
ACV ...................................... Air control valve
ATDC ............................. After top dead center
ASSY
.............................................. Assembly
BBDC
....................... Before bottom dead center
BTDC ............................ Before top dead center
EX ..................................................... Exhaust
IC .......................................... Integrated circuit
IG ....................................................... Ignition
IN ......................................................... Intake
INT
............................................... Intermittent
LH ................................................... Left hand
M
......................................................... Motor
1-3

OFF ................................................ Switch off
ON ................................................. Switch on
PCV Valve.... Positive crankcase
ventilation valve
PTC .................. Positive temperature coefficient
RH ................................................. Right hand
ST
.......................................................... Start
SW ...................................................... Switch
TDC ....................................... Top dead center
1-4

Section 2 - Maintenance and Lubrication
SECTION 2-
Maintenance and lubrication
SUBJECT PAGE
DESCRIPTION AND OPERATION
Engine Oil
Viscosity ................................ 2-2
Gasoline Octane Rating ........................... 2-2
Maintenance Schedules ........................... 2-3
Owner Maintenance Checks ..................... 2-3
Scheduled Maintenance- Emissions .......... 2-2
Vehicle Emission Control Information ........ 2-1
DESCRIPTION AND OPERATION
Vehicle Emission Control Information Decal
The Vehicle Emission Control Information Decal is
located on
the engine electrical panel right above
the coolant recovery bottle.
SUBJECT PAGE
DESCRIPTION AND OPERATION (continued)
Severe Maintenance Schedule
.................. 2-4
MAINTENANCE ......................................... 2-2
Maintenance Information ......................... 2-3
Normal Maintenance Schedule .................. 2-7
LUBRICATION ........................................... 2-9
Lubrication and Maintenance Chart ......... 2-10
2-1

Section 2 - Maintenance and Lubrication
VEHICLE EMISSION CONTROL INFORMATION- WESTWARD INDUSTRIES LTD.
ENGINE FAMILY: TWW1.3P8GAEA EVAPORATIVE FAMILY: TWW1065BYM07
TUNE-UP SPECIFICATIONS AND AD.JUSTMENTS (REFER TO YOUR OWNER'S MANUAL)
DISPLACEMENT: 1323 cc
VALVE LASH & HIGH ALTITUDE AD.JUSTMENT: Self adjusting
1. Before adjusting, connect test connector for Idle speed setting.
2. Set Idle speed and timing.
IDLE SPEED 850 RPM Transmission in Park "P".
IGNITION TIMING Adjust alignment mark at crank shaft pulley to timing indicator at idle.
3. Disconnect test connector.
1. Crank shaft pulley
2. Timing indicator
Cannister
3. Alignment mark
Fuel Tank
TYPE:SG
THIS VEHICLE CONFORMS TO U.S. EPA AND CALIFORNIA REGULATIONS APPLICABLE TO 1996 MODEL YEAR NEW
MOTORCYCLES AND IS CERTIFIED TO 1.4 g/km HC ENGINE FAMILY EXHAUST EMISSION STANDARD IN CALIFORNIA.
THIS MOTORCYCLE MEETS 1986 AND LATER EPA NOISE EMISSION REQUIREMENTS OF THE FEDERAL TEST PROCEDURE.
MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED FEDERAL NOISE STANDARD ARE PROHIBITED BY
FEDERAL LAW. SEE OWNERS MANUAL
LIMIT/CLOSING: 76 dBA/4300 RPM. 69-4001
Scheduled Maintenance -Emissions
The Emissions
Systems Required Maintenance
Schedule lists
the items required to maintain the
vehicle emissions systems at levels determined
by the Federal Government (Environmental
Protection Agency). Follow
the procedures to
perform the required emission system
maintenance items listed on the maintenance
schedules.
Maintenance service
must conform to the
specifications contained in this section, or to
those listed on the Vehicle Emission Control
Information Decal, or the emission systems may
become inoperative.
Gasoline
Octane Rating
The
G0-4 Interceptor is designed to use regular
unleaded fuel
with an octane rating of 87.
Using a fuel with a lower octane rating can cause
persistent and heavy knocking,
which can
damage
the engine.
If the vehicle is experiencing problems with
starting, rough engine idle, or hesitation when
the engine is cold, it may be caused by fuel with
low volatility. Inform the operator to use a
different grade and/or brand of fuel.
2-2
Engine Oil Viscosity
WARNING: CONTINUOUS CONTACT WITH
USED ENGINE OIL HAS CAUSED SKIN CANCER
IN LABORATORY MICE. PROTECT YOUR SKIN
BY WASHING WITH SOAP AND WATER.
Choose
the correct viscosity oil by considering
the temperatures the vehicle will be driven. The
use
of SAE 5W-30 is preferred in all climate
conditions. The use
of 1OW-30 is acceptable in
moderate climates. Using SAE 1OW-40 is
acceptable in
hot climates.
E:BR~:~
MAINTENANCE
1@1@1
MODERATE
TEMPERATURES
Perform the necessary scheduled maintenance to
assure the durability of the G0-4 and its emission
control
systems. Use genuine Westward
Industries parts for maintenance, repair and
replacement
of the emissions control devices and
systems.

Section 2 - Maintenance and Lubrication
Maintenance Information
The required Scheduled Maintenance Services
listed in
this section are considered important to
assure the proper operation, performance and
safety of the G0-4 Interceptor. It is
recommended
that the listed Owner Maintenance
Checks be performed. These services are regular
every
day care that is important to the proper
operation
of your vehicle. The recommended
fluids, lubricants and service
parts conform to
Westward Industries Ltd. specifications.
MAINTENANCE SCHEDULES
Maintenance schedules are based on
how the
vehicle is driven.
Regularly Scheduled Maintenance Intervals
The normal maintenance schedule should be
followed if, generally, the vehicle is driven on a
daily basis
for more than 10 miles and NONE OF
THE CONDITIONS IN THE SEVERE
MAINTENANCE SCHEDULE APPLY TO THE
DRIVING HABITS.
The Severe Maintenance Schedule should be
followed if the vehicle owner's driving habits
mainly include one
or more of the following:
1. Short trips of less than 10 miles ( 16 km)
when outside temperatures remain below
oo
F.
2. Operating when outside temperatures
remain
below freezing.
3. Operating during hot weather in stop-and-go
"rush
hour" traffic.
4. Extensive idling, such as police or door-to-
door service.
5. Operating
in extremely humid climates.
6. Driving in severe dust conditions.
7. Driving in area where road
salt or other
corrosives are used.
8. Driving on rough and/or
muddy roads.
Owner Maintenance Checks
The
following list of vehicle checks and
inspections should be performed
at the intervals
indicated.
Whenever You
Stop for Fuel
1. Check
the engine oil level.
2. Look for under-inflated tires.
At Least Monthly
1. Check tire pressure. Check tires when cold,
not after a long drive.
2. Check the coolant in the radiator coolant
recovery reservoir.
3. Check the operation of all exterior lamps
including
the brake lamps, turn signals, and
hazard warning flashers.
At Least Twice a Year
1. Check
the windshield wiper operation.
2. Check and replace worn windshield wiper
blades.
3. Check for worn tires and loose wheel hub
bolts.
4. Check pressure in the spare tire (option).
5. Check headlamp alignment.
6. Check the muffler, exhaust pipe, catalytic
converter, and clamps
for damage.
7. Check
the lap and shoulder belt for wear
and
function.
8. Check the radiator, heater, and air
conditioning hoses
for leaks or damage.
9. Check
the rear driveshaft joint boots for
cuts or leakage.
At Least Once a Year
1. Lubricate all hinges, checks, latches, roller,
and outside
key locks.
2. Lubricate the door rubber weather-strips.
3. Check
the air conditioning system (if
equipped) before
the warm weather season.
4. Clean door guide rails.
5. Check brake fluid level.
6. Clean battery connections and check fluid
level. Top up
if necessary.
2-3

Section 2 - Maintenance and Lubrication
7. Lubricate transaxle controls and linkage.
8. Inspect the refrigerant amount.
9. Inspect the A/C compressor operation.
Severe Maintenance Schedule
The Severe Maintenance Schedule should be
followed if the owner/operator's driving habits
include one
or more of the following:
1. Short trips of less than 10 miles.
2. Operating when outside temperatures
remain
below freezing.
3. Operating during hot weather in stop-and-go
"rush hour" traffic.
4. Extensive idling, such as police or door-to-
door service.
5. Operating in extremely humid climates.
6. Driving in severe dust/dirt conditions.
7. Driving in areas
where road salt or other
corrosives are used.
8. Driving on rough and/or muddy roads.
For
items marked with a number in brackets (1),
see
footnotes at the end of this section.
3,000 miles/5,000 km (200 hours)
• Change engine oil and replace oil
filter (4).
6,000 miles/10,000 km (400 hours)
• Change engine oil and replace oil filter (4).
• Rotate
tires and adjust air pressure.
9,000 miles/15,000 km (600 hours)
• Change engine oil and replace oil filter (4).
12,000 miles/20,000 km (800 hours)
• Change engine oil and replace oil filter (4).
15,000 miles/25,000 km (1 ,000 hours)
• Change engine oil and replace oil filter (4).
•
Inspect air cleaner element (1) (4).
•
Inspect front and rear disc brake pads and
rotors.
2-4
• Inspect bolts and nuts on chassis and body.
• Rotate tires and adjust air pressure.
18,000 miles/30 ,000 km (1 ,200 hours)
• Change engine oil and replace oil filter (4).
21,000 miles/35,000 km (1 ,400 hours)
• Change engine oil and replace oil filter (4).
• Change
automatic transmission fluid (2).
24,000 miles/40,000 km (1,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
27,000 miles/45,000 km (1 ,800 hours)
• Change engine oil and replace oil filter (4).
30,000 miles/50,000 km (2,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Replace air cleaner element (4).
• Inspect alternator and A/C compressor belts
(4).
• Check idle speed (3)(4).
• Change engine coolant every
30,000
miles/50,000 km (2,000 hours) or 36
months (4).
• Inspect engine cooling
system, hoses,
clamps: and check coolant
strength every
30,000 miles/50,000 km (2,000 hours) (4).
• Inspect fuel lines and hoses
(1 )(4).
• Inspect exhaust heat shield.
• Inspect rear wheel
driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
front fork assembly.
•
Inspect steering operation and linkage.
33,000 miles/55,000 km (2,200 hours)
• Change engine oil and replace oil filter.
• Rotate tires and
adjust air pressure.
36,000 miles/60,000 km (2,400 hours)
• Change engine oil and replace oil filter.
39,000 miles/65,000 km (2,600 hours)
• Change engine oil and replace oil filter.
42,000 miles/70,000 km (2,800 hours)
• Change engine oil and replace oil filter.

Section 2 - Maintenance and Lubrication
• Rotate tires and adjust air pressure.
• Change
automatic transmission fluid (2).
45,000 miles/75,000 km (3,000 hours)
• Change engine oil and replace oil filter.
• Inspect air cleaner element (1) (4).
• Inspect
front and rear disc brake pads and
front and rear disc brake rotors.
• Inspect
bolts and nuts on chassis and body.
48,000 miles/80,000 km (3,200 hours)
• Change engine oil and replace oil filter (4).
51,000 miles/85,000 km (3,400 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
54,000 miles/90,000 km (3,600 hours)
• Change engine oil and replace oil filter (4).
57,000 miles/95,000 km (3,800 hours)
• Change engine oil and replace oil filter (4).
60,000 miles/100,000 km (4,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive
belts (4).
• Replace air cleaner element (4).
• Inspect ignition
timing (1 )(4).
•. Check idle speed (3)(4).
• Change engine coolant every
30,000
miles/50,000 km (2,000 hours) or 36
months (4).
• Inspect engine cooling
system, hoses and
clamps; and check coolant
strength every
30,000 miles/50,000 km (2,000 hours) or
36 months (4).
• Replace fuel
filter (3) (4).
• Inspect fuel lines and hoses (3)(4).
• Inspect fuel hoses and
tube for emissions
(1 )(4).
• Inspect exhaust heat shield.
• Inspect rear wheel
driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
bolts and nuts on chassis and body.
• Inspect
front fork assembly.
• Inspect steering operation and linkage.
• Repack
front and rear wheel bearings.
• Rotate tires and adjust air pressure.
• Replace timing chain/belt. Failure
to replace
timing chain/belt
may result in damage to the
engine (3)(4).
• Inspect timing chain/belt(3)(4).
63,000 miles/105,000 km (4,200 hours)
• Change engine oil and replace oil filter (4).
• Change
automatic transmission fluid (2).
66,000 miles/110,000 km (4,400 hours)
• Change engine oil and replace oil filter (4).
69,000 miles/115,000 km (4,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
72,000 miles/120,000 km (4,800 hours)
• Change engine oil and replace oil filter (4).
75,000 miles/125,000 km (5,000 hours)
• Change engine oil and replace oil filter (4).
• Inspect air cleaner element
(1 )(4).
• Inspect
front and rear disc brake pads and
disc brake rotors.
• Inspect bolts and
nuts on chassis and body.
78,000 miles/130,000 km (5,200 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
81,000 miles/135,000 km (5,400 hours)
• Change engine oil and replace oil filter (4).
84,000 miles 140,000 km (5,600 hours)
• Change engine oil and replace oil filter (4).
• Change auto. transmission fluid (2).
87,000 miles/145,000 km (5,800 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
90,000 miles/150,000 km (6,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive
belts (4).
• Replace air cleaner element (4).
• Check idle speed (3) (4).
2-5

Section 2 - Maintenance and Lubrication
• Change engine coolant every 30,000
miles/50,000 km (2,000 hours) or 36
months (4).
• Inspect engine cooling
system, hoses and
clamps; and check coolant
strength every
30,000 miles/50,000 km (2,000 hours) or
36 months (4).
• Inspect timing chain/belt
(1 )(4).
• Inspect fuel lines and hoses
(1 )(4).
• Inspect exhaust shield.
• Inspect rear wheel driveshaft
joint boots.
• Inspect
front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
bolts and nuts on chassis and body.
• Inspect
front fork assembly.
• Inspect steering operation and linkage.
93,000 miles/155,000 km (6,200 hours)
• Change engine oil and replace oil filter (4).
96,000 miles/160,000 km (6,400 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
99,000 miles/165,000 km (6,600 hours)
• Change engine oil and replace oil filter (4).
102,000 miles/170,000 km (6,800 hours)
• Change engine oil and replace oil filter (4).
105,000 miles/175,000 km (7 ,000 hours)
• · Change engine oil and replace oil filter (4).
• Inspect air cleaner element
(1 )(4).
• Replace timing chain/belt (4).
• Inspect fuel hoses (4).
• Inspect
front and rear disc brake pads and
front and rear disc brake rotors.
• Inspect bolts and
nuts on chassis and body.
• Rotate tires and adjust air pressure.
• Change
automatic transmission fluid (2).
108,000 miles/180,000 km (7,200 hours)
• Change engine oil and replace oil filter (4).
111
,000 miles/185,000 km (7 ,400 hours)
• Change engine oil and replace oil filter (4).
114,000 miles/190 ,000 km (7 ,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
2-6
117,000 miles/195,000 km (7 ,800 hours)
• Change engine oil and replace oil filter (4).
120,000 miles/200,000 km (8,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive
belts (4).
• Replace air cleaner element (4).
• Check idle speed (4).
• Inspect ignition timing (1) (4).
• Change engine coolant every
30,000
miles/50,000 km (2,000 hours) or 36
months (4).
• Inspect engine cooling system. hoses and
clamps; and check coolant strength every
30,000 miles/50,000 km (2,000 hours) or
36 months (4).
• Replace fuel filter(4)(5).
• Inspect fuel line and hoses (4).
• Inspect fuel hoses and
tube for emissions
(4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft
joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
bolts and nuts on chassis and body.
• Inspect
front fork assembly.
• Inspect steering operation and linkage.
• Repack
front and rear wheel bearings.
• Replace timing chain/belt. Failure
to replace
timing/belt chain may result in damage to the
engine (4)(5).
FOOTNOTES:
1. This item is
not required to be performed,
however Westward Industries recommends
that you perform maintenance on this item
in order
to achieve best vehicle operation.
2. Change automatic transmission fluid if your
driving habits
frequently include one or
more of the following conditions:
• Operation during
hot weather (above
90° F, 32°C), carrying heavy loads or
driving in hilly terrain.
• Police or door-to-door delivery service.
3. This item is required
for all states.
4. These items are for emission control.
5. Required
for all states except California.

Section 2 - Maintenance and Lubrication
Normal Maintenance Schedule
The Normal Maintenance Schedule should be
followed if the vehicle is generally driven on a
daily basis
for more than 10 miles (16 km) and
NONE
OF THE CONDITIONS SHOWN IN THE
SEVERE MAINTENANCE SCHEDULE APPLY TO
DRIVING HABITS.
For
items marked with a number in brackets (1 ),
see
footnotes at end of this section.
5,000 miles/8,000 km (325 hours)
• Change engine oil and replace oil filter. (4)
• Rotate tires and adjust air pressure.
10,000 miles/16,000 km (650 hours)
• Change engine oil and replace oil filter (4).
15,000 miles/24,000 km (1 ,000 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
20,000 miles/32,000 km (1 ,325 hours)
• Change engine oil and replace oil filter (4).
25,000 miles/40,000 km (1 ,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate
tires and adjust air pressure.
30,000 miles/48,000 km (2,000 hours)
•. Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and
A/C compressor belts
(4).
• Replace air cleaner element (4).
• Check idle speed (2)(4).
• Change engine coolant every
30,000
hours/50,000 km (2,000 hours) or 36
months.
• Inspect engine cooling system, hoses and
clamps; and check coolant
strength every
30,000 miles/50,000 km (2,000 hours) or
36 months (4).
• Inspect fuel lines and hoses.
• Inspect exhaust
heat shield.
• Inspect rear
driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
front steering system.
• Inspect steering operation and linkage.
• Change
automatic transmission fluid.
35,000 miles/42,000 km (2,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
40,000 miles/48,000 km (2,650 hours)
• Change engine oil and replace oil filter (4).
45,000 miles/54,000 km (3,000 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
50,000 miles/60,000 km)(3,325 hours)
• Change engine oil and replace oil filter (4).
55,000 miles/66,000 km (3,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
60,000 miles/72,000 km (4,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and
A/C compressor drive
belts (4).
• Replace air cleaner element (4).
• Replace timing chain/belt (2)(4).
• Inspect ignition
timing (1)(4).
• Check idle speed (2)(4).
• Change engine coolant every
30,000
miles/50,000 km (2,000 hours) or 36
months (4).
• Inspect engine cooling system, hoses and
clamps; and check coolant strength every
30,000 miles/50,000 km (2,000 hours) or
36 months.
• Replace fuel filter (2)(4).
• Inspect fuel lines and hoses (2)(4).
• Inspect fuel hoses and
tube for emissions
(2)(4).
• Inspect exhaust heat shield.
• Inspect rear wheel
driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect
front steering assembly.
• Inspect bolts and
nuts on chassis and body.
• Inspect steering operation and linkage.
• Repack
front wheel and rear wheel bearings.
• Change
automatic transmission fluid.
65,000 miles/78,000 km (4,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate
tires and adjust air pressure.
2-7

Section 2 - Maintenance and Lubrication
70,000 miles/90,000 km (4,650 hours)
o Change engine oil and replace oil filter (4).
75,000 miles/90,000 km (5,000 hours)
o Rotate tires and adjust air pressure.
o Change engine oil and replace oil filter (4).
80,000 miles/96,000 km (5,325 hours)
o Change engine oil and replace oil filter (4).
85,000 miles/102,000 km (5,650 hours)
• Change engine oil and replace oil
filter (4).
• Rotate tires and
adjust air pressure.
90,000 miles/108,000 km (6,000 hours)
•
•
•
•
•
•
•
•
•
0
•
•
•
•
0
0
•
Change engine oil and replace oil filter (4).
Replace spark plugs (4).
Inspect alternator and
A/C compressor drive
belts (4).
Replace air cleaner element (4).
Check idle speed (2)(4).
Change engine coolant every
30,000
miles/50,000 km (2,000 hours) or 36
months (4).
Inspect engine cooling
system, hoses and
clamps; and check coolant
strength every
30,000 miles/50,000 km (2,000 hours) or
36 months.
Inspect timing chain/belt. (1 )(4).
Inspect fuel line and hoses
(1 )(4)..
Inspect exhaust
heat shield.
Inspect rear wheel driveshaft joint boots.
Inspect front and rear brakes.
Inspect brake lines, hoses and connections.
Inspect steering assembly.
Inspect bolts and nuts on chassis and body.
Inspect steering operation and linkage.
Change
automatic transmission fluid.
95,000 miles/114,000 km (6,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and
adjust air pressure.
100,000 miles (6,650 hours)
• Change engine oil and replace oil filter (4).
2-8
105,000 miles (7 ,000 hours)
• Change engine oil and replace oil filter (4).
• Replace
timing chain/belt (4).
•
Inspect fuel hoses (4).
• Rotate tires and
adjust air pressure.
110,000 miles (7,325 hours)
• Change engine oil and replace oil filter (4).
1
15,000 miles (7 ,650 hours)
o Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
120,000 miles (8,000 hours)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
0
Change engine oil and replace oil filter (4).
Replace spark plugs (4).
Inspect alternator and A/C compressor drive
belts (4).
Replace air cleaner element (4).
Inspect ignition timing
(1 )(4).
Check idle speed (2)(4).
Change engine coolant every
30,000 miles
(2,000 hours) or 36 months.
Inspect engine cooling system, hoses and
clamps; and check coolant
strength every
30,000 miles (2,000 hours) or 36 months.
Replace fuel filter (3)(4).
Inspect fuel lines and hoses (2)(4).
Inspect hoses and tube for emissions (1 )(4).
Inspect exhaust heat shield.
Inspect rear wheel driveshaft joint boots.
Inspect front and rear brakes.
Inspect brake lines, hoses and connections.
Inspect front fork assembly.
Inspect
bolts and nuts on chassis and body.
Inspect steering operation and linkage.
Repack
front and rear wheel bearings.
Replace
timing chain/belt. (3)(4).
Change
automatic transmission fluid.
FOOTNOTES:
1. This
item is not required to be performed,
however Westward recommends that you
perform maintenance on this item in order
to achieve best vehicle operation.
2. This item is required for all states.
3. Required for all states except California.