1981 cushman truckster manual

This way you reduce the recurring costs that come with wear parts. You also reduce the general machine costs because maintenance, wages and stalling is reduced to a minimum. This website uses cookies to ensure you get the best experience on our website. Learn more Got it!

Learn more. Filter results 59 results. Filter results Chosen filters Reset. Cushman Truckster parts. Replacement parts for Truckster Parts Cushman. Filter - air element - R Add a remark:. Starter - fits cushman tr - R Bearing - tapered - R Brandstoffilter - RDM-G Show next 24 results. Parts that fit the Cushman Truckster The different products for your Truckster are easily found in the parts manual.

Maintenance for the Cushman Truckster You want to keep the total cost of ownership and the cost per hour of your Truckster as low as possible.

Battery dead. Charge or replace Section Only on diesel engine powered vehicles does the accelerator foot pedal retain full control of throt- This section covers adjustments to speed controls, tle lever position. An internal engine governor parking and service brakes, power take off PTO adjusts the injector pump to compensate for varia- controls, clutch interlocks, transmission gear selectors With the accelerator pedal fully depressed, adjust 6.

With the accelerator pedal fully depressed, remove the second throttle stop screw see Figure 2C Pull the turnbuckle to the full throttle position see Install the turnbuckle pin, washer see Figure 2C Adjust the counterbalance and cotter pin so that the turnbuckle pin is snug spring by centering the jam nuts on the governor against the broken knee lever when pressure is Depress the accelerator pedal down against the pedal stop screw see Figure 2C With accelerator pedal fully depressed, check 7.

Push the broken knee lever to its full at rest posi- throttle plate. Pull spring bracket toward you, the tion see Figure 2C The parking brake activates only the two rear brakes of the vehicle. Raise the engine cover to gain access to the parking brake cables. This vehicle is equipped with four hydraulic 5.

Attach a hose to the bleeder screw on top of the brakes controlled by the brake pedal. Open the left rear dust shield and place the other end of the front cowl of the vehicle to gain access to the hose in a container to catch the fluid run-off when Depress clutch pedal, stop as soon as clutch resistance is felt, and measure clutch pedal free A clutch interlock switch allows the engine starter to travel as shown in Figure 2C Repair as necessary.

If the gear shift control lever can be shifted from neu- tral vertical position to and between 3rd and 4th positions smoothly, the gear select cable is adjusted Replace the entire panel if the tachome- ter, hour meter, fuel gauge, voltmeter or water tem- perature gauge are defective. See Section 10 for electrical testing. Anti-rust Never-Seize. Lubricants: See Section Other service items: Compressed air source. Engine hoist. Engine will not start. Parking brake disengaged. Engage brake.

Glow plug has not timed out b. Reset ignition switch and allow diesel. Diesel engines used on this vehicle are 3-cylinder, 4- cycle, liquid cooled Perkins Series.

The engine is equipped with a cooling radiator and an Unless the radiator is very low, always add coolant to electric cooling fan. Radiator and Cooling System Repair 3D Check rubber mountings for damage, deteriora- tion and out of position.

If nuts or bolts are loose, tighten them to 29 to 43 ft-lbs. A pre-filter is located in-line between the fuel fuel filters. Raise dump box and open engine cover. Using a suitable lifting device, lift engine and posi- tion in-line with transmission.

Disconnect NEG — battery cable from battery. Remove high tension coil cable at ignition coil 3-cylinder Suzuki or 4-cylinder Suzuki The basic components of this ignition system are igni- tion coil, distributor and spark plugs. The components of the distributor are signal generator signal rotor and pickup coil , igniter, rotor, cap and both vacuum and centrifugal advance.

Cleaning and rebuilding of carburetors Clean dust from inside of housing with damp cloth, making sure dust does not enter air intake. The engine is equipped with a cooling radiator and an With the park brake applied and the gear selector in electric cooling fan.

Remove negative — battery cable. Remove fuel filler cap from fuel filler neck to release fuel vapor pressure in fuel tank. Transmission 4-Cylinder Gasoline or Diesel Engines Blind hole bearing puller. Bearing and gear installation tools. Noisy when vehicle a. Excessive gear backlash. Adjust Section 4G or 4H. Faulty U-joints. Repair Section 4C. Clutch vibration. Glazed glass-like clutch facings a. Repair or replace Section 4D. Wobbly clutch disc or poor facing b. Transmission jumps a.

Shifting fork loose on shaft or a. Disassemble and check for wear out of gear. Transmission leakage.

Vent or breather clogged. Remove vent or breather and clean or replace Section 4G or 4H. Too much or improper lubricant. Disconnect control linkages and any cables that would prohibit pushing the drive shaft end of the The rear differential is driven by a universal joint type transmission downward about 4 inches. Start one bearing in yoke ear and position center cross through yoke. Drive Shaft Disassembly and Reassembly 4C Make certain that the yokes of the drive shaft are correctly aligned with the yokes in the transmis- sion and differential.

Install the drive shaft yoke onto the differential input shaft. See Figure 4D-1 for clutch arrangements. To gain access to the clutch components, either remove the engine as described in Section 3D or remove the transmission as described in Section 4H.

Clutch Repair 4. If the release bearing Figure 4D-3 sticks, rattles shown in Figure 4D-4 tap its end to remove bush- or makes abnormal noise when turned by hand, ing. Release Bushing Removal Figure 4D Checking Backlash in Disc Serration 4. Adjust shift controls as described in Section 2C. Figure 4E A pressure plate ring is used as an interface between the clutch disc and engine flywheel for diesel engine If necessary, repair the clutch as described in Section 4D.

Attach a suitable hoist to the transmission. The transmission is a 4 speed manual shift type. The 9. Remove hardware that fastens the transmission shift pattern is a standard H pattern with reverse R to the engine. Remove the mounting bolts, disengage the gear selector shaft from the gear shift lever in the transmission and lift the assembled gear shift case off the transmission case. Gear and Shaft Arrangement 4G Remove the rubber plug and retaining ring from the countershaft see Figure 4G Remove the two bolts securing the stop plate to the case.

Remove the stop plate, reverse idle gear and shaft see Figure 4G If any of these interlock balls are out of the 1. This will allow the spring pin to shift into the detent provided in the case.

Using a spring remover tool, draw out the spring pin and pull out the fork shaft. Check gear teeth for chips, see Figure 4G Check for broken or chipped spline teeth. Small chips may be blend-repaired in same manner as gear teeth. Inspect the external cone of the gear and internal cone of the ring for abnormal wear.

Normally, the entire transmission will not have been disassembled. When feeding each shifter fork onto its shaft, be 4. The shifter fork shafts are to be installed sequen- sure to bring the boss in which the hole for admit- tially. See Figure 4G for general arrangement of the countershaft, main shaft, input shaft and stop plate. Figure 4G When assembling the two synchronizer hubs on main shaft, be sure to position the hub of each correctly as shown in Figure 4G Key and Slot Alignment 5.

When joining the two cases as shown in Figure 4G, be sure to guide each shifter fork into the groove of its synchronizer sleeve. After putting the upper case on the lower case, tighten the joint bolts uniformly and sequentially so as to equalize the joint pressure all around. Install and tighten all transmission-to-frame that involves removal of the transmission from the mounting hardware.

Disconnect the drive shaft at the transmission see Section 4C. The shift pattern is a standard H pattern with reverse R 9. Gear and Shaft Arrangement 4H Use a bearing puller to pull the rear bearing see Figure 4H-6 off the countershaft. Remove the rear retaining ring and PTO drive gear. Figure 4H Input Shaft and Main Shaft 4H Remove bearing thrust washer and reverse gear 8.

Remove low gear, needle bearing and synchro- bushing on main shaft by using hydraulic press as nizer ring from main shaft as shown in Figure shown in Figure 4H Drive yoke pin out of high speed gear shift fork as in Step 3, on previous page, and pull out fork shaft and fork.

When removing yoke pin, be sure not to drive it out so far as to contact case, or it will cause damage to case. Clean parts in a suitable non-flammable solvent.

Check clutch teeth for rounding, see Figure 4H Check gear teeth for chips, see Figure 4H Face rounding will cause the clutch to jump out. Normally, the entire transmission will not have been Note that three shift shafts individually have a disassembled. Insert high speed gear shift shaft into upper case. Push down high speed gear shift shaft locating ball to pass shaft over it and keep inserting shaft until locating ball fits in center slot of 3 continuous slots in shaft.

See Figure 4H for general arrangement of the Be careful to install each washer, gear, synchro- countershaft, main shaft and input shaft. Install 2nd gear bearing, 2nd gear, synchronizer 5. For proper direction, 1. Drive countershaft front bearing into lower case. Countershaft Reassembly 4. Our scooter has a fresh c I have Yep, once again the Pawluk Brothers have lost their minds and are delighted to have Highly collectible today the Cushman motorcycle was a unique, simple and highly con Used Cushman Mailster for sale in Hershey, PA Vehicle Description CC 3 speed, new brakes, new brake drums, new tires, wiring is good, windshield is broke but I have another windshield, removable doors This would be great to use on a small farm to ride the grandkids around!