Chassis Maintenance

Weekly

Check and maintain oil level
Check and maintain coolant Level
Check and maintain brake fluid level
Wash and clean the car. Seal off air filter, tank vent, and exhaust. If using a pressure washer, be careful not to spray high pressure in the ECU ignition box, Power Commander, bearing seals, universal joint, rubber boot of the master cylinder, splines of steering column, and tank vent.
Lubricate the following:
- all rod ends
- universal joint
- splines of sliding steering column
- shock shaft and eyes
- shifter and wing adjuster shafts
- threads on splined rear axle
- nylon bushings on wing sliders
- steering quick release
- master cylinder shaft
- pedal pivot points
- throttle cable
Remove and clean front and rear sprocket, chain, and carburetor. Dry with compressed air. Apply chain lube to chain from the inside of the chain, it will then work its way out during rotation
Using a waterproof grease in a grease gun, grease the spindles
Check all fasteners and electrical connections, tighten if necessary
Inspect brake pads. Make sure you use brake pad spacers, if not the piston will extend too far and bind as pads wear
Inspect all radius rods, shocks, axles, steering arms, steering box, and wheels for bent or binding items. They may look straight, but if you rotate them or put a straight edge on them, you may find otherwise.
See our fuel injection maintenance page for injection considerations
Clean and check 2-stroke carburetor
If you run chain tensioner wheels, check these and replace if worn out, nylon guide blocks need to be replaced about every 20 races
Make sure the torsion bars and upper steering shaft move freely, ream bushings if needed.

Every 4 Races

Repack the front wheel bearings with grease and use a grease gun to grease the rear bearings
Change 600cc engine oil every 3-4 races if using cheap oil, change every 8 races if using AmsOil or other high quality synthetic.
Change 2-stroke transmission oil every
Change 600cc spark plugs every 10-15 races, change 2-stroke spark plugs every 4 races
Check Jacob's ladder and replace if lateral play develops
Check gas pressures if running monotube shocks

Every 25 Races

Replace king pins and king pin bushings
Replace upper steering shaft bushings
Replace the wing slider bushings(if applicable)
Inspect wheel bearings and replace if necessary by removing the front hubs and bearing carriers. On each bearing, turn the inner race by hand. The bearing should spin perfectly smooth. If any grinding, drag, or uneven rotation is felt, the bearing must be replaced. Front bearings Rear Bearings if you remove the dust cap, replace the o-ring
Replace chain if it is a standard chain, DID ERV3 gold chains replace after 40 races
Replace 600cc throttle cable and 2-stroke throttle cable

At Season End or 40 -60 races

Purge methanol from fuel delivery system, see our fuel injection maintenance page for more information.
Rebuild the master cylinder, install a new master cylinder rebuild kit
Replace brake line and possibly fittings
Replace torsion bars and torsion bar bushings
Inspect and replace if lip is forming on rear brake rotor and front brake rotor
Rebuild the rear brake caliper by replacing the square o-rings, pistons, pads, o-ring, and bleeder valves
Rebuild the HBS front brake caliper by replacing the square o-rings, pistons, pads, o-ring, and the bleeder valve
Inspect and replace if necessary:
- rack box for wear and play, these can be sent out for rebuild, for old style(frame mounted) rack box, replace wear bar and adjust play
- steering quick release (the new splined style can last for years)
- universal joints (usually need replaced every 60 races)
- all rod ends
Check seat belts for fraying replace every 2 years
Twin tube shocks need rebuilt every 40 races, monotube shocks every 90 races. Send to us or directly to ARS for rebuild.
Replace 600cc connecting rods every 60 races, rings every 15-30 races.
Replace bearings in the adjustable throttle pedal assembly
Exercise the driver so he stays in shape!

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Chassis Maintenance