Page 1 NUDA 900 2012/2013 NUDA 900 R 2012/2013 Workshop Manual Ed. 11-2011 Rev 02...
Page 2 M.28 Delete note. HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from actual components. No reproduction in full or in part without written authorisation.
Page 3: Workshop Manual
FOREWORD, TABLE OF CONTENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Workshop Manual NUDA 900 2012/2013 NUDA 900 R 2012/2013 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel.
Page 4 NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.
Page 5 FOREWORD, TABLE OF CONTENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Table of Contents Title Section Foreword, Table of Contents ................a Important Notices ....................b General Information .....................A Maintenance ......................B Troubleshooting ....................C Settings and Adjustments ................... D General Procedures ....................E...
Page 7 IMPORTANT NOTICES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 8 IMPORTANT NOTICES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 GENERAL SAFETY WARNINGS Read these general recommendations carefully before using the vehicle. Carbon monoxide Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction system.
Page 9 IMPORTANT NOTICES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Battery Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being recharged; do not smoke or use naked flames or sparks. The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water.
Page 10 IMPORTANT NOTICES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 RECOMMENDED SHOP PRACTICES Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or foreign bodies. Put the vehicle in a well lit area; Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts.
Page 11 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 12 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Engine ......................A.3 Timing system ....................A.3 Lubrication ....................A.3 Ignition ......................A.3 Fuel system ....................A.3 Primary drive ....................A.3 Clutch ......................A.3 Transmission ....................A.3 Secondary drive....................A.4 Final ratios ....................A.4 Chassis ......................A.4 Front suspension ..................A.4 Rear suspension...................A.4...
Page 13 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Engine Type ....... inline twin cylinder, 4 stroke, with four valves per cylinder Cooling ................liquid and electric fan Bore ..................3,31 in. (84 mm) Stroke ..................3,19 in. (81 mm) Displacement ................
Page 14 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Secondary drive transmission sprocket (NUDA 900) ............Z 17 Transmission sprocket (NUDA 900 R) ............Z 16 Rear wheel sprocket ................... Z 42 Transmission ratio (NUDA 900) ..............2.47 Transmission ratio (NUDA 900 R) .............2.625 Transmission chain dimensions ..........
Page 15: General Information
GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear brake Type ....... fixed disc ø 10,43 in. (ø 265 mm) and floating calliper Rims Front .................in light alloy: 3.5”x17” Rear ..................in light alloy: 5.5”x17” Tyres Front ....................120/70xZR17” Rear .....................180/55xZR17” Cold tyre pressure Front ................32,71 psi (2.3 kg/cm Rear .................41,25 psi (2.9 kg/cm Weight, capacity Kerb weight, without fuel.
Page 16 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Electrical components location The ignition system includes the following elements: Generator on the inner side of R.H. crankcase half cover; Electronic ignition coil with integrated spark plug cap positioned on cylinder head;...
Page 17 GENERAL INFORMATION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Dimension Wheelbase ................ 58,86 in. (1495 mm) Overall length ..............86,22 in. (2190 mm) Overall width ............... 35,16 in. (893 mm) Max. height ................ 48,03 in. (1220 mm) A= Seat height (NUDA 900) ..........34,25 in. (870 mm) A= Seat height (NUDA 900 R) ......34,45 ÷...
Page 19 MAINTENANCE NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 20 MAINTENANCE NUDA 900 2012/2013 - NUDA 900 R 2012/2013 NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) ENGINE SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON After the EVERY...
Page 21 MAINTENANCE NUDA 900 2012/2013 - NUDA 900 R 2012/2013 NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER) CHASSIS CHECKS SERVICE SERVICE SERVICE SERVICE SERVICE COUPON COUPON COUPON COUPON COUPON EVERY After the...
Page 23 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Manuale d'officina Ed. 11-2011...
Page 24 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE Trouble Possible causes Remedy Ignition switch not in ON position Switch ignition switch to position ON Engine-stop-switch on OFF position Switch to position ON Starter motor does not operate or does not...
Page 25 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Trouble Possible causes Remedy Excessive spark plug electrode gap Exchange spark plug Adjust valve clearance according to spe- Valve clearance below specification cification Tighten intake socket or exchange if ne- Intake socket not tight or leaking...
Page 26 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Trouble Possible causes Remedy Use fuel of specified octane number (min. Fuel of too low octane number ROZ 95) Spark plugs not according to specifications Replace spark plug or defective Engine knocks or pings...
Page 27 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Trouble Possible causes Remedy Not enough engine oil in the engine Refill oil Pressure regulating piston blocked (bypass Check/replace pressure regulating piston valve stuck in opened position) Check / replace oil pump and/or oil pump...
Page 28 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Trouble Possible causes Remedy Noise is heard when the engine is started: Sprag clutch, sprag clutch housing or fre- Replace Sprag clutch, sprag clutch housing ewheel gear worn or freewheel gear...
Page 29 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Trouble Possible causes Remedy Fatigue of clutch springs Replace clutch springs Clutch slips Clutch plates worn or warped Replace clutch plates Engine oil not according to specifications Exchange engine oil Engine oil not according to specifications...
Page 30 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 CHASSIS Trouble Cause Remedy Insufficient tyre pressure Inflate Bearing adjuster ring nut or steering stem Adjust nut overtightened Handlebar turns hard Bent steering stem Replace bottom yoke Worn or seized steering bearings...
Page 31 TROUBLESHOOTING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Dirty air filter Clean Spark plug fouls easily Worn piston rings Replace Worn piston or cylinder liner Replace Spark plug electrode gap too close...
Page 33 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 34 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Saddle removal.....................D.3 Central cover removal ..................D.4 Side panel removal ..................D.5 Throttle cable adjustment ................D.5 Throttle control....................D.6 Front brake control ..................D.6 Position adjustment ..................D.6 Front brake lever adjustment and fluid level check ........D.7 Clutch control....................D.8...
Page 35 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Saddle removal Turn the pin (1) counter-clockwise at approx. 90° and remove the saddle (2) to the rear part unhooking it from the front brackets. H10662 H10663 Workshop Manual Ed. 11-2011...
Page 36 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Central cover removal Insert the key in the lock and remove the cap (1). H10664 Remove the screw (2) under the cap. H10665 Loosen the five screws (3) that fasten the cover (4) and remove it.
Page 37 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Side panel removal Remove the saddle as described in the relevant paragraph. Loosen the five screws (1) and remove the right-hand side (2). Perform the same procedures for the removal of the left-hand side.
Page 38 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Throttle control The throttle twistgrip is located on the right-hand side of the handlebar: Throttle position adjustment The position of the control on the handlebar can be adjusted by loosening the two retaining screws (2).
Page 39 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front brake lever adjustment and fluid level check The lever (1) can be set to five different positions according to the size of the rider’s hand. To decrease the lever (1) distance from the handgrip, turn the adjuster screw (2) COUNTER CLOCKWISE “A”.
Page 40 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Clutch control The clutch control lever (1) is located on the left-hand side of the handlebar. Position adjustment The position of the clutch control on the handlebar can be adjusted by loosening the retaining screws (2).
Page 41 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Clutch free play adjustment Free play (A) must be 5 -10 mm (0.196 - 0.39 in). It can be adjusted by turning and adjuster screw on the clutch cover.
Page 42 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear brake fluid level check The fluid level in the master cylinder tank shall never be below the minimum level (1) shown on the transparent reservoir (2). A decrease in the fluid level will let air into the system and increase the lever stroke.
Page 43 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Engine oil replacement and cartridge filter replacement Be careful not to touch hot engine oil. Drain the oil with WARM ENGINE; proceed as follows: - Place the motorcycle on the side stand;...
Page 44 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Coolant level check When the engine is cold, check that the coolant level is between the two MIN and MAX marks on the expansion tank (1) on the right side of the vehicle.
Page 45 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Loosen the screw (2) of the lower pipe (3) that connects the radiator (4) to the exchanger (5). H10692 - Remove the exchanger pipe (3) and let the coolant drain in the bucket; dur- ing the reassembly, replace the seal (6).
Page 46 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Remove the radiator cap (9). - Loosen the coolant bleed screw (10) on the water pump cover and at the same time continue to pour liquid in the radiator until it comes out of the hole of the bleed valve, then tighten again the bleed valve (10).
Page 47 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Air filter check - Remove the upper cover as described in the relevant section. - Disconnect connector (1) of the air temperature sensor. - Unscrew the two screws (2) that fasten the side panels at the front.
Page 48 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chain adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or too tight), it could jump out of the sprocket or break.
Page 49 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Lubricating the chain Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets.
Page 50 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Suspension The vehicle leaves the factory with standard settings for the front and rear suspension that meet most requirements. On "NUDA 900" motorcycles, the front fork cannot be adjusted whereas the hydraulic rebound on the rear shock absorber can be adjusted.
Page 51 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 NOTE: Fork springs and shock absorbers with varying degrees of stiffness are available above all for use with passenger and/or panniers. H10705 NOTE: Do not go beyond 385 mm.
Page 52 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear shock absorber Depending on the installed rear shock absorber model, it is possible to per- form different adjustments as reported in the following table: H10706 SHOCK ABSORBER NUDA 900 NUDA 900...
Page 53 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Spring preload adjustment NUDA 900 - Remove the fuel tank as described in the relevant paragraph. - Clean the lock ring nut (1), and adjuster ring nut (2) on the spring (3) and the threading on the body of the shock absorber.
Page 54 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Spring preload adjustment NUDA 900 R Proceed as follows: 1. Clean the lock ring nut (1), the adjuster ring nut (2) on the spring (3) and the threading on the body of the shock absorber.
Page 55 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Adjustment shock absorber length NUDA 900 R Remove the fuel tank as described in the relevant paragraph. Loosen the upper pin (1) that fastens the shock absorber (2) to the chassis.
Page 56 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Shock absorber hydraulic damping adjustment Nuda 900 The shock absorber can be adjusted in the rebound hydraulic damping. B) REBOUND - Standard setting: Adjuster 1: - 25 clicks (± 2 clicks) To reset the standard setting, turn lower adjuster (1) clockwise until reaching fully closed position.
Page 57 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fork adjustment NUDA 900 On the fork installed on this motorbike version, it is not possible to perform any type of adjustment. Fork adjustment NUDA 900 R a) COMPRESSION (LOWER ADJUSTER)
Page 58 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fuel supply hose inspection and replacement Check fuel supply hose (1) conditions; if cracked, swollen, kinked, etc. it is nec- essary to change it as follows: - Remove the saddle, the right-hand side as outlined in the relevant sections.
Page 59 SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Exhaust system check Perform a visual inspection of the exhaust system first, in order to identify pos- sible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.
Page 61 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 62 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Stand removal / replacement................E.3 Stand foot replacement ................E.4 Saddle removal.....................E.5 Air-Box cover removal ..................E.6 Side panels removal ..................E.7 Number plate holder removal ...............E.7 Tail light removal ...................E.9 Rear turning indicator removal ..............E.10 Tail removal ....................E.13...
Page 63 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Stand removal / replacement Loosen the nut (1) and remove the rotary type switch (2). H10722 H10723 Release the spring (3). Loosen the screw (4) and remove the stand (5).
Page 64 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Stand foot replacement Loosen the screw (7) and replace the foot (8) by reinstalling it exactly as the figure shows. H10726 H10728 Workshop Manual Ed. 11-2011...
Page 65 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Saddle removal Turn the pin (1) around 90° counter-clockwise and remove the saddle (2) to the rear part unhooking it from the front brackets. H10662 H10663 Workshop Manual Ed. 11-2011...
Page 66 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Air-Box cover removal Insert the key in the lock and remove the cap (1). H10664 Remove the screw (2) under the cap. H10665 Loosen the five screws (3) that fasten the cover (4) and remove it.
Page 67 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Side panels removal Remove the saddle as described in the relevant paragraph. Loosen the five screws (1) and remove the right-hand side (2). Perform the same procedures to remove the left-hand side.
Page 68 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the two upper screws (7). H10732 Tilt the number plate holder (4) to the right and to the left, and remove it. H10733 Workshop Manual Ed. 11-2011...
Page 69 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tail light removal Remove the number plate holder as described in the relevant paragraph. Remove the O-ring (1) that fasten the cables. H10734 Loosen the two screws (2) with the related bushings and remove the tail light (3).
Page 70 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear turning indicator removal Remove the number plate holder as described in the relevant paragraph. Remove the tail light as described in the relevant paragraph. Loosen the two screws (1) that fasten the passenger handle (2).
Page 71 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the four self-tapping screws (4). Loosen the two screws (5) that retain the turning indicators (6). H10740 Remove the lower cover (7). H10741 Disconnect the two connectors (8) and (9), and remove the two turning indi- cators (6).
Page 72 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 In case of replacement of the harness (10), cut the clamp (11), disconnect the number plate bulb holder (12), replace the harness (10) and reinstall it exactly in the same position by fastening it with the clamp (11) and passing it behind the tab (13).
Page 73 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tail removal Remove the saddle, the sides and the number plate holder as described in the relevant paragraphs. Loosen the five screws (1) and remove the tail (2) slipping it off towards the rear part.
Page 74 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front fairing removal Loosen the two screws (1) and remove the spoiler (2). H10749 H10750 Workshop Manual Ed. 11-2011 E.14...
Page 75 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front turning indicator removal Remove the front fairing as described in the relevant paragraph. Disconnect the connector (1) of the left-hand indicator and the connector (2) of the right-hand indicator.
Page 76 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Combined dashboard removal Remove the front fairing as described in the relevant paragraph. Disconnect the connector (1). H10755 Remove the retaining clip (2) and remove the dashboard (3). During the reassembly, insert the pins in the special rubbers and lock the dashboard with the special retaining clips.
Page 77 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front mudguard removal Loosen the six screws (1) that fasten the mudguard (2) to the fork making sure to retain the bushings (3). Lift and slightly turn the mudguard (2), then remove it.
Page 78 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front mudguard fin removal Loosen the screw (1) and remove the fin (2); during the reassembly, fit the tab (3) in the special seat (4), then tighten again the screw (1).
Page 79 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Battery removal Make sure that the ignition switch has been turned to OFF and that the key has been removed; – loosen the three screws (1); H10763 remove the cover (2);...
Page 80 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Reservoir removal Disassemble the saddle, the sides, the number plate holder and the tail as described in the relevant paragraphs. Disconnect the oil pump supply connector (1). Loosen the two screws (2) and remove the pump delivery fitting (3).
Page 81 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the four screws (9) (two per side) that fasten the small chassis (11) to the chassis (10). Remove the small chassis (11) with the reservoir (12) towards the rear side of the bike.
Page 82 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fuel pump removal Disassemble the saddle as described in the relevant paragraph. Disconnect the connector (1). Disconnect the fuel pipe (2) by loosening the two screws; collect the fuel that could come out.
Page 83 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fuel pump inspection Remove the pump as described in the relevant paragraph. Connect the positive pole (12V) of the power supply to the pin of the red cable in the pump connector;...
Page 84 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Filter box removal Remove the fuel tank as described in the relevant paragraph. Disconnect and remove the connector (1) of the air temperature. H10779 Disconnect the connector (2) of the idle air actuator (Stepper motor).
Page 85 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the two front screws (5). H10783 Lift the filter box (6). H10784 Open the clamp (7) and remove the Blow-By pipe (8); remove the filter box (6). During the reassembly, the throttle control cable (9) must pass over the pipe (8).
Page 86 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Throttle body removal Remove the reservoir and the filter box as described in the relevant para- graphs. Remove the throttle body (1) from the harness. Disconnect the connector (2) from the injectors.
Page 87 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Exhaust system removal H10925 1. Silencer 2. Clamp 3. Exhaust valve actuator starter motor 4. Lambda sensor 5. Manifold 6. Gasket Workshop Manual Ed. 11-2011 E.27...
Page 88 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Exhaust system removal Remove the radiator and the reservoir as described in the relevant para- graphs. Remove the protection (1) by loosening the screws (2). H10793 Loosen the nuts (3) and disconnect the cables (4) that control the exhaust valve.
Page 89 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the nuts (9) of the exhaust manifold (10). H10798 Disconnect the connector (11) of the Lambda sensor. H10799 Cut the clamp (12). Loosen the central screw (13) of the manifold support (10).
Page 90 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 H10803 During the reassembly, check the seals (14) for wear, replace if damaged. H10804 Lambda sensor removal Remove the fuel tank as described in the relevant paragraph. Disconnect the connector (1).
Page 91 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Coil / Stick-Coil removal and spark plug test ÷ 0.035 in) Spark plug electrodes gap shall be 0.8 ÷ 0.9 mm (0.031 A wider gap may cause difficulties in starting the engine and overload the coil.
Page 92 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Horn removal Unscrew the screw (1). Disconnect the connector and remove the horn (2). H10810 Radiator removal Remove the saddle and the right-hand panel as described in the relevant paragraphs.
Page 93 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the screw (6). H10814 Cut the fan harness retaining clamp (7). H10815 Disconnect the connector (8) of the fan. H10816 Remove the radiator (9) from the right-hand side of the bike, by removing it from the special clips.
Page 94 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 During the reassembly, make sure that the pins (10) and (11) fit in the support (12) and (13) respectively. H10818 H10819 Electric fan removal Remove the radiator as described in the relevant paragraph.
Page 95 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Battery housing removal Remove the battery, the reservoir, the oil reservoir, and the voltage regulator, as described in the relevant paragraphs. Loosen and remove the upper pin (1) of the shock absorber, then tilt the shock absorber to the rear part of the bike.
Page 96 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the screw (8) in the right-hand side, the screw (9) in the left-hand part and the two screws (10) in the rear part. H10825 During the reassembly, position again correctly the bushings (11).
Page 97 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Engine removal Remove in a sequence the following components, as described in the relevant paragraphs/chapters: Filter box; reservoir; radiator with the respective pipes; rear shock absorber and rear swinging arm;...
Page 98 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the screw (10) on the left side and the screw (11) on the right side keeping the spacer (12). H10832 H10833 Disconnect from the engine the cable (13) of the clutch.
Page 99 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the harness (14) from the bike by cutting the retaining clamps. Loosen the screws (15) from the left side and the screws (16) from the right side. Lift the chassis (17) by removing it from the engine.
Page 100 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Engine reassembly Remove the battery support (1) from the engine by loosening the screws (2). Insert the new clamps (3) in the slots and reinstall the battery support (1). H10837...
Page 101 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Reinstall the chassis (4) on the engine and, from the left-hand side, screw manually the screws (5) fully home without tightening then, from the right-hand side, tighten manually the screws (6) fully home by interposing the related spacers (7).
Page 102 GENERAL PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 H10844 H10845 Install the swinging arm (8) without tightening the nut to torque (9) of the pin (10). Tighten the screws (5) on the left-hand side of the chassis to torque.
Page 103 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed. 11-2011...
Page 104 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario VALVE CLEARANCE CHECK ..............F.3 Checking cylinder “1” valve clearance ............F.3 Valve clearance measurement ..............F.3 Checking cylinder “2” valve clearance ............F.3 HALF-BALL REPLACEMENT............... F.4 Locking the crankshaft..................
Page 105 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 VALVE CLEARANCE CHECK Remove the coil / spark plug cap and the head cover as described in chapter "F1". Checking cylinder “1” valve clearance: Turn the crankshaft in the normal direction of engine rota - tion until cylinder “1”...
Page 106 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 HALF-BALL REPLACEMENT Turn the engine in the normal rotation direction until the marks IN and EX on the camshaft gears are facing each other and are positioned level with the sealing surface.
Page 107 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chain tensioner disassembly Remove the screw (1) with the sealing ring (2). Remove the spring (3) and the chain tensioner (4) from the hole. H10188 Camshaft mount disassembly Loosen all the nuts (2) uniformly in a diametrically opposite order and remove them.
Page 108 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Insert the half-balls (2) slightly lubricated with engine oil between the rocker arm (1) and the valve. Only half-balls marked with an identification number ("XXX") may be used. Half-balls without an identification number must be elimi- nated.
Page 109 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Camshaft mount assembly Check that the sliding element (1) is not worn and replace it if necessary. Clean the sealing surfaces. - Lubricate the new sealing rings (2) with engine oil and fit them. Before fixing the mount, make sure that the axial camshaft guide is correctly positioned (arrow).
Page 110 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the locking screw (7) and re-tighten the screw (8) to torque, replac- ing the gasket (9). - Recheck valve clearance before refitting the head cover. H10196 H10197 Workshop Manual Ed. 11-2011...
Page 111 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 TIMING CHECK Remove the coil / spark plug cap and the head cover as described in chapter "F1". Remove the screw (1) with the sealing ring (2). H10200 Check the position of the camshaft gears.
Page 112 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE PHASING Proceed as follows to rephase the engine. Remove the head cover as described in chapter "F1". Lock the crankshaft as previously described. Chain tensioner disassembly Remove the screw (A) with the sealing ring (B).
Page 113 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Camshaft mount assembly Check that the sliding element (1) is not worn and replace it if necessary. Clean the sealing surfaces. - Lubricate the new sealing rings (2) with engine oil and fit them. Before fixing the mount, make sure that the axial camshaft guide is correctly positioned (arrow).
Page 114 ENGINE SETTINGS AND ADJUSTMENTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Insert the chain tensioner, replacing the gasket (9) and activate it manually to tension the timing chain, checking that the timing is correct, then tighten the screw (10) to torque.
Page 115 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Refer to chapter F4 for all the engine tightening torques. Workshop Manual Ed. 11-2011 F1.1...
Page 116 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario LEFT CLUTCH SIDE COVER REMOVAL/INSTALLATION ......F1.3 Gearbox lever removal/installation .............F1.3 Oil dipstick removal ..................F1.3 Cover removal ....................F1.3 Gearbox selector shaft oil seal removal/installation ........F1.4 Clutch disengagement shaft removal ............F1.4 Clutch disengagement shaft oil seal removal ..........F1.4...
Page 117 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 LEFT CLUTCH SIDE COVER REMOVAL/INSTALLATION When installing a new crankcase cover, the bearings and the gaskets are preassembled. Gearbox lever removal/installation Removal: Loosen the screw (1) then remove the lever (2).
Page 118 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Gearbox selector shaft oil seal removal/installation Using a screwdriver, carefully remove the oil seal from the inside diameter (1). Lubricate the seal lip of the new oil seal; then fit it on the cover, using an appropriate tool.
Page 119 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Clutch disengagement shaft oil seal installation Lubricate the oil seal lip (1) with engine oil. Install the shaft oil seal (1) with the thrust spindle. The open side of the sealing ring is located inside.
Page 120 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Left engine crankcase cover assembly Turn the bevelled edge (1) of the clutch presser to the installation position (see figure) between the holes (arrow). The space washer (2) must engage on the gearbox shaft.
Page 121 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 RIGHT ENGINE CRANKCASE REMOVAL/REPLACEMENT Remove the screws (1). Remove the cover (2) with the gasket (3). H10223 Stator disassembly Remove the screws (4). Remove the cable gland (3). Remove the screws (1).
Page 122 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Right engine crankcase cover installation Apply a layer of sealant (Three-Bond 1209) on the sealing surface of the rubber sheath (2). H10227 Clean the sealing surfaces. Fit the new gasket (3) and the engine crankcase cover (2).
Page 123 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 FLYWHEEL AND STARTER MOTOR IDLE GEAR REMOVAL Remove the right crankcase and fix the engine at the top dead centre, as described in the relevant paragraphs. Remove the screw (1) with the washer.
Page 124 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Starter motor idle gear removal/installation Remove gears (1) and (2) and check the state of wear, refit them exactly in the correct position, making sure that a space washer is fit above the idler gear (1).
Page 125 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 CRANKSHAFT POSITION SENSOR REMOVAL/INSTALLATION Remove the screw (1). Disassemble the crankshaft position sensor (2), remove the gasket (3). Upon reassembly, replace the gasket (3) and tighten the screw (1) to the correct tightening torque (using Loctite 243).
Page 126 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 STARTER MOTOR REMOVAL/INSTALLATION Removal: Remove the screws (1). Extract the starter motor, paying attention to the sealing ring (2). H10240 Installation: Check the sealing ring (2) for damage and replace it if necessary.
Page 127 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 GEAR POSITION SENSOR REMOVAL/INSTALLATION Removal: Remove the screws (1). Disassemble the gearbox potentiometer (2) with the sealing ring (3). Check the oil seal (4) for wear; if there are leaks, replace it.
Page 128 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 REMOVAL/INSTALLATION OF THE COMPLETE CLUTCH Removal: Remove the gearbox lever, the left crankcase cover and fix the engine at the top dead centre, as described in the relevant paragraphs.
Page 129 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Disassemble the clutch housing (12), paying attention to the needle roller bearings (13) and the space bushing (14). H10249 Disassemble the control gear (15) and the thrust washer (16).
Page 130 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Lubricate the needle roller bearings (13) with engine oil. Insert both needle roller bearings (13) with the space washer (14) in the clutch housing (12). Fit the clutch housing (12) all the way down, paying attention to the oil pump gears.
Page 131 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Insert the actuator pin (4) in the pressure plate (5) and fit the pressure plate (5). Insert the flanged bushings (2) on the springs (3) and fit the springs on the pressure plate (5).
Page 132 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 OIL PUMP Oil suction pump removal/installation Removal: Remove the sprocket casing as described in the relevant paragraph. Remove the screws (1). Disassemble the cover (2) with the gasket (3).
Page 133 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Oil force pump removal/installation Remove the complete clutch as described in the relevant paragraph. Removal: Disassemble the retaining ring (4) and the washer (3). Disassemble the gear (2). Disassemble the drive pin (1).
Page 134 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Installation: Clean all components prior to installation and lubricate them with engine oil. Insert the pin (9) in the shaft. Place the rotating piston (7) on the shaft with the mark (10) facing outwards, paying attention to the correct positioning of the pin (9).
Page 135 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 COOLANT PUMP REMOVAL/INSTALLATION Removal: Drain the coolant as indicated in the relevant paragraph. Open the pipe clamps (1) using a suitable tool and disconnect the pipes (2) from the radiator (3) and from the pump cover (4).
Page 136 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the control gear (13). H10276 Check that the hole (14) in the engine cylinder head is not blocked and clean it if necessary. Clean the seat of the pump in the engine cylinder head.
Page 137 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 necessary), making sure the hole (21) is not blocked. Clean the hole (21) if necessary. Do not clean the hole with compressed air. Apply a layer of Three-Bond 1209 on the contact surface of the pump body (A).
Page 138 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fully tighten the screws based on the sequence (1) - (5). H10284 Fix the pipe clamps (5) carefully checking that the tabs of the clamps are facing towards the rear.
Page 139 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Replace the control gear (7) on the camshaft with a new part. Replace the water pump as described in the relevant paragraph. H10288 Installation: Clean the threading and the washer (5).
Page 140 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 OIL SUMP REMOVAL/INSTALLATION Removal: Drain the oil from the engine as described in the relevant paragraph. Remove the screws (1) and the oil sump (2). Installation: Clean the sealing surfaces.
Page 141 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 SWING ARM COVER REMOVAL/INSTALLATION Removal: Disassemble the oil sump as described in the relevant paragraph. Remove the screws (1) and the gasket (2). H10431 Remove the screws (3). Remove the cover (4).
Page 142 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the screws to torque, referring to the installation sequence (from 1 to 11). Refit the oil sump as described in the relevant paragraph. H10432 OIL PRESSURE ADJUSTMENT VALVE CHECK/REPLACEMENT Removal: Remove the swing arm cover as described in the relevant paragraph.
Page 143 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 TIMING CHAIN REMOVAL/REPLACEMENT (ENGINE REMOVED) Perform the following operations, as described in the relevant paragraphs, before disassembling the timing chain: Drain the engine oil. Remove the oil filter. Remove the starter motor.
Page 144 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 If the timing chain (4) is reused, mark the rotation direction before removing Take the timing chain (4) off the sprocket and remove it. H10302 Remove the screw (5).
Page 145 GENERAL ENGINE PROCEDURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fit the caps (2), paying attention to the correct positioning of the centring pins and the installation position marks. NOTE: The caps (2) must not be inverted. Replace the screws (1) and tighten them manually.
Page 147 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed. 11-2011 F2.1...
Page 148 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Removal of the ignition coil from the spark plug recess ......F2.3 Cylinder head cover removal/installation ............F2.3 Chain tensioner removal/installation............F2.4 Locking the crankshaft................F2.5 Crankshaft locking screw removal ..............F2.5 Camshaft mount disassembly ..............F2.6 Camshaft mount assembly .................F2.6...
Page 149 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Removal of the ignition coil from the spark plug recess Remove the ignition coil from the spark plug recess (1). H10311 Cylinder head cover removal/installation Removal: Remove the screws (1).
Page 150 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Replace the rubber bushings (6) and the screws (1). H10314 Clean the sealing surfaces and the gaskets. Check and if necessary replace the sealing ring (5). Position the head cover (2) paying attention to the breather opening (arrow).
Page 151 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Locking the crankshaft Remove the head cover as described in the relevant paragraph. Rotate the engine in the normal direction of rotation until the marks IN and EX on the camshaft gears are facing each other and are level with the seal- ing surface.
Page 152 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Camshaft mount disassembly Loosen all the nuts (2) uniformly in a diametrically opposite order and remove them. Remove the slider (3) with the support (4). Remove the camshaft mount (1).
Page 153 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the crankshaft locking screw (7) and re-tighten the screw (8) to torque (see chapter “F4”), replacing the gasket (9). - Recheck valve clearance before refitting the head cover. H10196 H10197 Workshop Manual Ed. 11-2011 F2.7...
Page 154 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Camshaft removal/replacement Removal: - Fix the engine at the TDC, remove the camshaft mount and remove the chain tensioner as described in the relevant paragraphs. First lift the intake camshaft (2) and then the exhaust camshaft (1) with a suitable tool, making sure not to damage the sealing surface. - Remove the timing chain (3) first from the intake camshaft sprocket, and then from the exhaust shaft and fix it in a suitable point to prevent it from falling.
Page 155 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Clean the threading and the washer (8) of the intake camshaft (2). - Clean the contact surface and fit the driving wheel (6). Tighten the screw (7) (left-hand threading) with the washer (8) locking the shaft with the socket (9).
Page 156 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Timing chain slider replacement - Remove the chain tensioner, the camshafts and the clutch cover as described in the relevant paragraphs. Unscrew the screw (1). Remove the mobile chain tensioner slider (2) towards the top. H10332 - Remove the fixed slider (3) of the timing chain towards the top. H10334 Check the chain sliders for wear and replace them if worn.
Page 157 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rocker arm removal/installation or replacement Removal: Remove the camshafts as described in the relevant paragraph. The half-balls can fall inside the cylinder head oil ducts. Plug ducts with a cloth.
Page 158 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Cylinder head removal/installation - replacement of cylinder head gasket - Remove the camshafts, timing chain sliders as described in the relevant paragraphs. Removal: Unscrew the screws (1). Unscrew the screws (2).
Page 159 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Cylinder head disassembly If the head is replaced, also the camshaft mount must be replaced. The spare head is supplied together with the mount. Remove the cylinder head as described in the relevant paragraph. Remove the cooling pump as described in the relevant paragraph.
Page 160 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Using a suitable tool, pre-load the valve spring (5), remove the valve collets (6) and then release the valve spring. Remove the upper valve spring retainer (7) and the valve spring (5) Remove the bottom valve spring retainer (8). Remove the valves (9).
Page 161 CYLINDER HEAD REMOVAL/DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Fit the intake couplings (2) and fix them with the clamps (1), being careful to position their hooks downwards. Fit the temperature sensor (3). - Refit the rocker arms, the cooling pump and the head as described in the relevant paragraphs. H10350 Workshop Manual Ed. 11-2011 F2.15...
Page 163 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Refer to chapter F4 for all engine tightening torques. Workshop Manual Ed. 11-2011 F3.1...
Page 164: Crankcase Disassembly
CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario CRANKCASE DISASSEMBLY ..............F3.3 Gearbox removal ..................F3.4 Gearbox output shaft disassembly .............F3.5 Gearbox input shaft disassembly ...............F3.7 Shift drum star removal ................F3.8 Ratchet removal ..................F3.8 Gearbox fork removal .................F3.8 Gear selection drum removal ..............F3.9 Gear selection drum disassembly ..............F3.9...
Page 165 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 CRANKCASE DISASSEMBLY With the engine removed from motorcycle, remove the following components before disassembling the crankcase. Remove the cylinder head. Remove the heat exchanger. Remove the starter motor. - Remove the oil filter.
Page 166 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Turn the lower part of the engine upwards. Remove the safety pin (3). Using a suitable puller, remove the pin (4) of the compensation arm (5). Rotate the compensation arm (5) upward.
Page 167 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Gearbox output shaft disassembly Remove the retaining ring (1). Remove the bearing (2), being careful not to damage the gear and the bear- ing seat. H10357 Extract the washer (3).
Page 168 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 During operation, the gear pairs slide towards each other. If just one coupling gear is replaced, the load bearing capacity on gears may become significantly worse. Replace the paired gears, but one at a time! All components must be checked before being installed.
Page 169 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Gearbox input shaft disassembly Remove the bearings (1) and (2) with a suitable tool, being careful not to damage the gear and the bearing seat. H10364 Extract the idle wheel (3).
Page 170 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fit the bearings (1) and (2) with a suitable tool, being careful not to damage the gear and the bearing seat. H10367 Shift drum star removal Remove the shift drum star as follows: Plug the openings in the crankcase with rags.
Page 171 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the fork pin (4). Remove the engagement fork (5) of the 5 gear. H10371 Gear selection drum removal Remove the screw (1). Remove the drum (2) from the lower crankcase half.
Page 172 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Installation: Heat the drum in the area of the internal bearing to approx. 80°C. Fit the inner bearing (4) using a press, making sure that the bearing rests correctly on its seat.
Page 173 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Mark the pistons and the relevant cylinders. Do not exchange the components: mark the assembly positions. Remove the split bearings (3) from the two caps (2). H10379 Mark the exhaust side on the pistons.
Page 174 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Main split bearing removal Mark the installation positions of the split bearings. Remove the split bearings (1) from the upper crankcase, the split bearings (2) of the main bearing caps and the split bearings (3) of the lower crankcase.
Page 175 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Piston ring removal Remove the piston rings and the scraper ring using suitable pliers. Visually check the grooves of the piston rings. H10387 Piston ring assembly Insert a metal wire (3) through the two eyelets of the undulated torsion spring (2), leave an equal length of wire on both sides, do not shorten it.
Page 176 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Piston installation - When fitting the piston pin, make sure that the version of the pin and the connecting rod are the same. Lubricate the piston pins with engine oil. Heat the piston to approx. 50°C. Insert the connecting rod and the piston pins (2), paying attention to the installation position.
Page 177 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chain tensioning slider installation Clean the threading. Insert the chain tensioner slider (2) and tighten the screw (1) to the required torque. H10393 Main split bearing installation Turn the upper crankcase of the engine and support the pistons inside the cylinders.
Page 178 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Main bearing cap installation Clean and lubricate all support surfaces. Fit the caps (2), making sure the reference pins (3) are correctly positioned. Pay attention to the installation position marks.
Page 179 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Compensation arm installation Insert the split bearings with the prong (arrow) in the connecting rod caps and in the compensation arm. H10400 Clean and lubricate all the connecting rod separation surfaces.
Page 180 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Gear selector drum installation Clean the threading. Clean the control roller and the supporting points and lubricate them with engine oil. Fit the selector drum with the bearing (2) in the section of the crankcase.
Page 181 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Star-shaped stop element installation Move the ratchet to the side (1) with a screwdriver and insert the start-shaped stop element (3); correctly insert the pin (4) in the hole (5) of the drum.
Page 182 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Installation of the lower part of the engine crankcase half Apply a layer of sealant on the lower part of the crankcase. Accidentally plugging the throttle valve or the oil channel damages the gearbox, because the main oil supply is interrupted.
Page 183 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Check that the crankshaft split bearings (1) are inserted correctly in their seats. Lubricate the split bearings with engine oil. H10414 When inserting the lower part of the engine crankcase half, pay attention to the centring pins.
Page 184 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fixing the compensation arm Orient the compensation arm (3) downwards. Press the bearing pin down fully. Use a suitable tool to insert the pin (2) in the compensation arm. Fit the safety pin (1).
Page 185 CRANKCASE DISASSEMBLY NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the screws to torque in the installation sequence from 12 to 23. H10423 Gearbox output shaft oil seal installation Fill the new oil seal between the inner sealing lips with grease.
Page 187 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Tighten all nuts and screws to the specified torque using a torque wrench. An insufficiently tightened screw or nut could get damaged or come completely loose, damaging the motorcycle and/or injuring the rider. A screw or nut tightened beyond the permitted max.
Page 188 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 : Lubricate with engine oil. : Grease. : Tighten manually. CONVERSION TABLE 1 Nm = 0.1 Kgm 1 Nm = 0.73756 ft/lb Workshop Manual Ed. 11-2011 F4.2...
Page 189 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 12 Nm 30 Nm Klueber 46 MR 12 Nm Loctite 648 10 Nm Loctite 5910 12 Nm Loctite 648 19 Nm 19 Nm 12 Nm 25 Nm 12 Nm...
Page 190 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 12 Nm 12 Nm Loctite 243 12 Nm Loctite 243 30 Nm 14 Nm 12 Nm 1) 5 Nm 40 Nm 12 Nm 10 Nm 2) 20 Nm H10455 Workshop Manual Ed.
Page 191 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 1) 10 Nm 2) 30 Nm 3) 135° 1) 5 Nm, 2) 20 Nm 3) 95° 1) 5 Nm 2) 20 Nm 3) 95° H10456 = Replace the screws at each reassembly! Workshop Manual Ed.
Page 192 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 10 Nm 1) 30 Nm 2) 270° 10 Nm 19 Nm 30,5 mm ± 1 mm 20 Nm 17 mm ± 1 mm H10457 = Replace the screws and the head gasket at each reassembly! Workshop Manual Ed.
Page 193 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 10 Nm 40 Nm 50 Nm Loctite 243 10 Nm Loctite 243 H10458 Workshop Manual Ed. 11-2011 F4.7...
Page 194 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 10 Nm Loctite 243 10 Nm Three Bond 1209 H10459 Workshop Manual Ed. 11-2011 F4.8...
Page 195 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 12 Nm 12 Nm 5 Nm Loctite 243 30 Nm 10 Nm Three Bond 1209 Klueber 46 MR 401 H10460 = Left-hand thread Klueber 46 MR 401 50 Nm...
Page 196 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 5 Nm Loctite 243 10 Nm 10 Nm Loctite 243 10 Nm Loctite 243 H10462 Workshop Manual Ed. 11-2011 F4.10...
Page 197 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Klueber 46 MR 401 180 Nm Loctite 648 10 Nm H10463 Workshop Manual Ed. 11-2011 F4.11...
Page 198 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 12 Nm H10464 Workshop Manual Ed. 11-2011 F4.12...
Page 199 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Three Bond 1209 10 Nm 4 Nm Loctite 243 11 Nm ± 12% 10 Nm Loctite 243 140 Nm Loctite 648 35 Nm Loctite 648 Klueber 46 MR 401...
Page 200 ENGINE TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 12 Nm H10466 Workshop Manual Ed. 11-2011 F4.14...
Page 201 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011 F5.1...
Page 202 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Engine wear value table ................F5.3 Crankshaft / Casing assy................F5.3 Connecting rod ...................F5.3 Compensation connecting rod compensation arm ........F5.3 Gearbox ......................F5.4 Gear shift control ..................F5.5 Clutch ......................F5.6 Piston......................F5.6...
Page 203 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Crankshaft / Casing assy. Radial clearance / Crankshaft / Casing assy. 4 bearing points, in direc- Crankshaft - Main bear- 0.03 - 0.06 mm...
Page 204 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point min. Ø 21.98 mm No signs of pitting are Ø compensation pin Compensation pin Ø...
Page 205 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Visual check of the teeth sides (small grey marks and individual pits up to approx.
Page 206 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Clutch Clutch plates - permitted 9 1.5 mm steel plates max. 0.15 mm max.
Page 207 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Piston pin min. Ø 17.98 mm Detachments in the DLC Ø piston pin PISTON PIN 18/11x50 Ø...
Page 208 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Valves With cold engine (max. Intake valve clearance Intake valve 33 mm 0.23 - 0.33 mm...
Page 209 WEAR LIMITS OF ENGINE PARTS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 ENGINE WEAR VALUE TABLE Description Part Measurement New value [mm] Wear limit [mm] Remarks point Oil pump Sliding clearance be- Delivery pump / Intake tween the inner and the max.
Page 211 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 212 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Front end ...................... I.3 Disassembly ....................I.4 Assembly ...................... I.6 Suspension settings summary tables ............I.8 Servicing forks .................... I.10 Bushings and seals replacement..............I.13 Assembly ....................I.14 Servicing of the damper................I.15 Damper reassembly ...................
Page 213 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front end H10576 Steering nut. Fork leg retaining screws. Steering head. Ring nut. Bottom yoke. Bearings. Dust seal. Washer. Workshop Manual Ed. 11-2011...
Page 214 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Disassembly Remove the wheel, the headlight, the front mudguard as described in the rel- evant paragraphs. Loosen the four screws (1) and move the handlebar without removing it. Protect carefully the fairings and the painted parts to prevent scratches and/or damages.
Page 215 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fully loosen the nut (2) and remove the steering head (5). H10581 Loosen the ring nut (6) and remove the bottom yoke (7) with the related bearings (8) and the dust seal (9).
Page 216 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Assembly For the reassembly of the front end, proceed as follows: Lubricate the bearings with grease before reassembling them. Install the bottom yoke (1), the upper bearing (2) and the dust seal (3), the...
Page 217 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Insert the fork stems (7) and position them depending on the type of use as described in the following table; lock them in position by tightening the lower screws (8) to torque.
Page 218 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 The different adjustments in the table must be performed both on the front fork and on the rear shock absorber. Suspension settings summary tables SHOCK ABSORBER NUDA 900 NUDA 900...
Page 219 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the nut (6) to torque. H10631 Tighten the upper screws (9) of the fork leg stems to torque. Reassemble in reverse order the other components that were previously removed.
Page 220 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Servicing forks NOTE: only for NUDA 900 R: Before starting the fork servicing procedures, make note of its set- ting (compression, rebound, pre-load), then position the adjuster screws on the maximum opening.
Page 221 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Loosen the cap (1) from the rod. H10590 Remove the spring (4). H10591 Remove the adjuster rod (6) inside the damper rod (7). H10592 Turn the fork sleeve (2) upside down so the oil can come out.
Page 222 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Lock the foot (8) with a vice with aluminium jaws. H10594 Insert the proper tool in the fork leg to lock the bushing of the damper. H10595 Fit the tool in the respective seats of the damper so that it does not turn while you loosen the valve assembly.
Page 223 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Remove the bottom valve assembly (9). H10598 Remove the damper (10) from the fork sleeve. H10599 Bushings and seals replacement Use a screwdriver to remove the dust seal (11) making sure not to damage H10600 - Use a flat head screwdriver to remove the retaining ring (12).
Page 224 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Open with light hits the fork leg (13) from the fork sleeve (2) until they sepa- rate. H10602 Remove the bushings and the sealing rings from the fork leg. Check the bushings for wear and tear. If they show wear replace them.
Page 225 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Insert again the fork leg (13) in the fork sleeve (2). H10606 With a suitable tool, press on the sealing ring (14) until it is fully inserted in the seat.
Page 226 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Heat the area of the bushing (15) in order to remove the Loctite. H10610 Loosen the bushing (15) with a suitable tool. H10611 Remove the bushing (15) with the damper rod.
Page 227 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Damper reassembly Insert again the rod assembly (7) in the damper (10). H10614 Tighten the bushing (15) with Loctite 243 using a suitable tool. H10615 Insert again the damper assembly (10) in the fork leg (13).
Page 228 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the bottom valve to torque (50 Nm, 5 Kgm, 36.88 ft/lb). H10618 Insert again the adjustment rod (6). H10619 Pour the oil in the fork sleeve (2): - 598 cc. for NUDA 900;...
Page 229 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Possibly, use a syringe to correct the level. H10622 Insert a spring (4) and possibly a pre-load tube. H10623 Tighten the cap (1) on the rod (20 Nm, 2.0 Kgm, 14.75 ft/lb).
Page 230 FRONT SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 NOTE: only for NUDA 900 R: At the end, restore the adjustments that were recorded before the servicing procedures. H10626 Workshop Manual Ed. 11-2011 I.20...
Page 231 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 232 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Rear suspension....................J.3 Rear shock absorber removal ...............J.3 Rear shock absorber spring replacement............J.4 Mudguard / chain guard removal ..............J.6 Sprocket casing removal ................J.7 Rear swinging arm removal ................J.8 Chain upper slide removal ................J.9 Chain lower slide removal ................J.10...
Page 233 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear suspension This motorcycle suspension is direct. The spring pre-load of the shock absorber can be adjusted to suit riding and terrain conditions. With regard to the hydraulic adjustments, refer to the chapter “Settings and Adjustments”.
Page 234 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear shock absorber spring replacement Put soft jaws on the vice and lock the shock absorber. Fully loosen until the end stroke the lock ring nut (1) and the ring nut (2) in order to discharge the spring (3).
Page 235 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Check the ring nuts (1) and (2) and the washer (5) for wear: if they show wear or they are damaged, replace them. Install the new spring, tighten the ring nut (2) and restore the correct length (pre-load) as the drawing “A”...
Page 236 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the lock ring nut (1) to torque. H10926 Mudguard / chain guard removal Loosen the screws (1) and remove the mudguard / chain guard (2) slipping it off towards the rear side.
Page 237 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 During the reassembly, make sure that the bushings are correctly positioned and that the rear brake hose (3) and the speed sensor wire (4) are correctly inserted in their respective seats.
Page 238 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear swinging arm removal Position a suitable support under the engine and fasten the bike so that it does not move. Remove the wheel and the chain mudguard as described in the relevant paragraphs.
Page 239 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chain upper slide removal Position a suitable support under the engine and fasten the bike so that it does not move. Remove the wheel and the sprocket casing as described in the relevant paragraphs.
Page 240 REAR SUSPENSION NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chain lower slide removal Loosen the screw (1), turn the slider (2) and remove it downwards. H10656 H10657 H10658 Workshop Manual Ed. 11-2011 J.10...
Page 241 BRAKES NUDA 900 2012 - NUDA 900 R 2012 NON-ABS version MY12 only Section Workshop Manual Ed. 11-2011...
Page 242 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Sommario Braking system ..................... L.3 Brake disc ..................... L.5 Rear braking system removal ............... L.6 Front braking system removal ..............L.8 Checking brake pads for wear / replacing the pads ........L.10 Brake fluid replacement ................
Page 243 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Braking system The braking system uses two independent circuits. Each circuit is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front master cylinder 3.
Page 244 BRAKES NUDA 900 2012 - NUDA 900 R 2012 9. Rear brake fluid reservoir 10. Rear line 11. Rear brake calliper 12. Rear brake disc 13. Rear master cylinder 14. Rear brake control pedal H10850 H10851 Workshop Manual Ed. 11-2011...
Page 245 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: mm 320 (12.6 in.).
Page 246 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Rear braking system removal - Remove the rear wheel (1) and the chain/mudguard casing (2) as described in the relevant paragraph. H10855 - Unhook the spring (3), loosen the three screws (4) and remove the cover (5), so the master cylinder is free.
Page 247 BRAKES NUDA 900 2012 - NUDA 900 R 2012 - Loosen the screw (8) and remove the cable ring (9). - Cut the clamps that fasten the system. - Loosen the screw (10) and remove the speed sensor (11). - Remove the calliper (12) with the whole system.
Page 248 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Front braking system removal To remove the front braking system from the vehicle, you must separate the var- ious components; then you should empty the liquid from the system as follows: - Remove the rubber cap (1) of the coupling (2) of one of the two callipers.
Page 249 BRAKES NUDA 900 2012 - NUDA 900 R 2012 - Loosen the drilled bolt (10) and disconnect the brake pipe (11) from the mas- ter cylinder. H10929 - Loosen the two screws (12) and remove the full lever (13). During the reassembly, position the front brake pipe in the original position with the respective clamps, then pour the oil in the reservoir and bleed the system as described in the relevant paragraph.
Page 250 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 4 mm - (0.157 in.) (front and rear pads) If said limit has been exceeded, or if even only one of the wear indicators is no longer visible, replace the pair of pads (in any case, the replacement is neces- sary when the wear indicators are no longer visible).
Page 251 BRAKES NUDA 900 2012 - NUDA 900 R 2012 REPLACEMENT FRONT BRAKE PADS NUDA 900 Loosen the two screws (1) and remove the calliper (2). H10868 Remove the two safety clips (3). Slide out the two pins (4) and remove the metal sheet (5).
Page 252 BRAKES NUDA 900 2012 - NUDA 900 R 2012 FRONT BRAKE PAD REPLACEMENT - NUDA 900 R Loosen the screws (1) and remove the calliper (2). H10931 Prize with a screwdriver in order to remove the pads (3) from the seat (4) in the body of the calliper.
Page 253 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Brake fluid replacement For the replacement of the braking system fluid, first of all you need to drain the existing fluid. Fluid replacement and system bleeding Brake fluid should be checked and changed as per the "Maintenance Chart"...
Page 254 BRAKES NUDA 900 2012 - NUDA 900 R 2012 - Remove the cover (3) with the respective gaiter of the oil reservoir (4). - Pull the lever (5) of the brake and keep it pulled, loosen the valve (2) and wait for the oil to come out, then tighten the valve (2) and release the lever (5).
Page 255 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding is also required after changing brake fluid.
Page 256 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Remove the cover (3) of the fluid reservoir (4), the rubber gaiter and fill the reservoir with fresh fluid. Pull the lever (5) of the brake and keep it pulled so that the system remains under pressure, loosen the valve (2), tighten the valve (2) always with the lever pulled, then release the lever.
Page 257 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Remove the cover (1) of the fluid reservoir (2), the rubber gaiter and fill the reservoir with fresh fluid.
Page 258 BRAKES NUDA 900 2012 - NUDA 900 R 2012 Periodically check the connecting hoses (C) and (D) (see Scheduled Mainte- nance Chart, Section B): if they show signs of wear or damage, replace them. H10880 H10881 Workshop Manual Ed. 11-2011...
Page 259 BRAKES NUDA 900 2013 - NUDA 900 R 2013 ABS version MY13 only Section Workshop Manual Ed. 11-2011 L1.1...
Page 260 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Sommario Braking system (ABS) ................L1.3 Brake disc ....................L1.6 Removing the braking system ..............L1.7 Replacing a brake line ................L1.8 Diagram of location of lines ................ L1.8 Front braking system removal ..............L1.10 Removing the front brake calliper .............
Page 261 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Braking system (ABS) The braking system uses two independent circuits. The master cylinders and callipers are connected to a control unit which modulates the pressure in each of the two circuits to prevent the wheels from locking up under braking. ABS circuit diagram H12018 X.
Page 262 BRAKES NUDA 900 2013 - NUDA 900 R 2013 7. Front brake lever 8. Front master cylinder 9. Front oil reservoir H12019 10. Right-hand front brake calliper line 11. Right-hand front brake calliper 12. Left-hand front brake calliper 13. Left-hand front brake calliper line 14.
Page 263 BRAKES NUDA 900 2013 - NUDA 900 R 2013 18. Rear brake calliper 19. Rear brake disc 20. Rear master cylinder 21. Rear brake control pedal 22. Rear tone wheel 23. Rear speed and ABS sensor 24. Rear brake fluid reservoir 25.
Page 264 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: mm 320 (12.6 in.). Front brake disc thickness (when new): mm 4.5 (0.177 in.).
Page 265 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Removing the braking system Removing the ABS unit Remove the tank, the filter box and the rear wheel as described in the relative paragraphs. The new ABS unit is supplied pre-filled with fluid. Brake fluid is highly corrosive and may cause skin irritation; place absorbent paper around the ABS unit to absorb any spilled fluid. H12027 - Drain the fluid from the front and rear brake systems as described in the relative paragraphs.
Page 266 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Replacing a brake line - Drain all the fluid from the relative braking system (front or rear). - Replace the damaged line, routing and fastening the new line (with clamps and hose guides) exactly as before and replacing all the seal washers. - Fill the system with fluid and bleed as described in the relative paragraph.
Page 267 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Front system 1) Line connecting ABS unit to distributor. 2) Line connecting front brake master cylinder to ABS unit. 3) Line connecting distributor to right-hand front calliper. 4) Line connecting distributor to left-hand front calliper. 5) Hose ring.
Page 268 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Front braking system removal To remove the front braking system, the individual components of the system must be separated. After separation, drain the components of brake fluid as described in the paragraph “Changing brake fluid”. Do not spill brake fluid onto any painted surface or lens (for example lights lens).
Page 269 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Removing the front master cylinder - Loosen the drilled bolt (5) and disconnect the brake pipe (6) from the master cylinder. - Undo the two screws (7) and remove the lever complete with the master cylinder (8).
Page 270 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Removing the rear master cylinder - Unhook the spring (1), loosen the three screws (2) and remove the cover (3), so the master cylinder is free. H12044 - Loosen the screw (4) and remove the oil reservoir (5). H12045 - In case you need to replace the master cylinder (6), open the clamp (7) and detach the pipe (8) collecting the oil that comes out of the reservoir, then...
Page 271 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Removing the rear brake calliper - Loosen the screw (3) and remove the speed sensor (4). - Undo the threaded bolt (5) and remove the brake calliper (6), collecting any fluid remaining in the line. During reassembly, refit the rear brake lines in exactly the same positions as before, replacing all the seal washers and fastening with the relative clamps as indicated in the paragraph “Replacing a...
Page 272 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 4 mm - (0.157 in.) (front and rear pads) If said limit has been exceeded, or if even only one of the wear indicators is no longer visible, replace the pair of pads (in any case, the replacement is neces- sary when the wear indicators are no longer visible).
Page 273 BRAKES NUDA 900 2013 - NUDA 900 R 2013 REPLACEMENT FRONT BRAKE PADS NUDA 900 Loosen the two screws (1) and remove the calliper (2). H10868 Remove the two safety clips (3). Slide out the two pins (4) and remove the metal sheet (5). Replace the brake pads (6).
Page 274 BRAKES NUDA 900 2013 - NUDA 900 R 2013 FRONT BRAKE PAD REPLACEMENT - NUDA 900 R Loosen the screws (1) and remove the calliper (2). H10931 Prize with a screwdriver in order to remove the pads (3) from the seat (4) in the body of the calliper.
Page 275 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Brake fluid replacement For the replacement of the braking system fluid, first of all you need to drain the existing fluid. Fluid replacement and system bleeding Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water.
Page 276 BRAKES NUDA 900 2013 - NUDA 900 R 2013 - Remove the cover (3) with the respective gaiter of the oil reservoir (4). - Pull the lever (5) of the brake and keep it pulled, loosen the valve (2) and wait for the oil to come out, then tighten the valve (2) and release the lever (5).
Page 277 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding is also required after changing brake fluid.
Page 278 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Remove the cover (3) of the fluid reservoir (4), the rubber gaiter and fill the reservoir with fresh fluid. Pull the lever (5) of the brake and keep it pulled so that the system remains under pressure, loosen the valve (2), tighten the valve (2) always with the lever pulled, then release the lever.
Page 279 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: Remove the cover (1) of the fluid reservoir (2), the rubber gaiter and fill the reservoir with fresh fluid.
Page 280 BRAKES NUDA 900 2013 - NUDA 900 R 2013 Periodically check the connecting hoses (C) and (D) (see Scheduled Mainte- nance Chart, Section B): if they show signs of wear or damage, replace them. H12051 H10881 Workshop Manual Ed. 11-2011 L1.22...
Page 281 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 282 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Wiring diagram MY12 .................. M.5. Key to wiring diagram MY12 ..............M.7 Wiring diagram MY13 .................. M.9 Key to wiring diagram MY13 ..............M.11 Electrical component location ..............M.12 Checking generator stator windings resistance ......... M.16 Generator performance ................
Page 283 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Stand rotative switch replacement............. M.48 12V plug replacement................M.48 Water temperature sensor replacement ............ M.49 Troubleshooting ..................M.5.0 Charging system..................M.5.0 Starting system ..................M.5.0 Electronic ignition system ................M.5.0 Electrical connectors positioning ...............
Page 284 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Workshop Manual Ed. 11-2011...
Page 285 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Wiring diagram MY12 17 19 20 39 40 H10467 Workshop Manual Ed. 11-2011...
Page 287 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Key to wiring diagram MY12 Clutch control lever Left-hand switch Control unit ECU Throttle opening position sensor Diagnostic connector Injector 1 Anti-theft device (Optional) Injector 2 12V current plug Coil / spark plug 1...
Page 288 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 INTENTIONALLY WHITE PAGE Workshop Manual Ed. 11-2011...
Page 289 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Wiring diagram MY13 H12126 Workshop Manual Ed. 11-2011...
Page 290 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Workshop Manual Ed. 11-2011 M.10...
Page 291 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Key to wiring diagram MY13 Colour key Control unit ECU blge ....blue / yellow Diagnostic connector blgn ....blue / green Anti-theft device (Optional) blrt....blue / red 12V current plug blsw ....
Page 292 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Electrical component location Generator (1) inside the right-hand cover; H10468 Electronic ignition coils (2) integrated with spark plug cap positioned on the cylinder head; Spark plugs on the cylinder head;...
Page 293 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Starter motor (5.) on the front part of the engine; H10472 Starter relay (6) on the central part behind the battery; H10473 Throttle opening position sensor (7) on the throttle body;...
Page 294 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Battery (10) 12V - 12Ah on the central part of the right-hand side; H10476 A 30A fuse (11) on the solenoid starter; H10477 Relays on the front side near the control unit: - Relay (12): main;...
Page 295 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Electric fan (16) on the rear part of the radiator. H10480 Headlamp (17) with H4 12V-5.5./60W twin halogen lamp and 12V-5.W parking light bulb; LED tail light (18); Turning indicators (19), 12V-6W bulbs;...
Page 296 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Checking generator stator windings resistance (1) Disconnect the stator coil connector from the wiring and measure resistance with a meter. H10468 1) Measure across the terminals of the connector (2); correct value is about 0.1 - 1.0...
Page 297 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Gear position sensor Positioned in the left-hand side of the engine, under the sprocket casing. H10935 Crankshaft position sensor Positioned on the rear right-hand side of the engine. H10937 Workshop Manual Ed. 11-2011...
Page 298 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Ignition and injection system The engine ignition and injection system is controlled by the electronic control unit (ECU) which controls the status of the engine and the surrounding environ- ment at each moment with a series of sensors.
Page 299 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Charging system The charging system is composed of: - Battery (1); - Voltage regulator (2); - Alternator (3). The alternated current generated by the alternator is converted into direct cur- rent by the voltage regulator.
Page 300 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Charging system inspections Battery Remove the protection panel (as described in the relevant paragraph) to gain access to the battery (1). Disconnect the BLACK negative cable from the battery. Measure current across the negative terminal of the battery and the negative cable using an ammeter clamp.
Page 301 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Electric starting system The starting system is composed of: - ECU (1). - Battery (2); - Starter relay (3); - Starter motor (4); - Fuse box (5.); - Ignition (6);...
Page 302 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Starting system inspection Starter motor inspection For the inspection of the starter motor (1), proceed as follows: - connect a meter across ground (3) and starter motor contact (2). - Check for continuity between the positive pole and motor ground. If no continuity is found, replace the starter motor.
Page 303 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Coil windings / Stick-Coil inspection Disconnect the connector (1). Lift the coil / Stick-Coil (2) to remove it. Measure the resistance of the primary and secondary winding with a me- ter.
Page 304 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Spark plug Check electrode gap "A" (0.8 ÷ 0.9 mm) (0.0315. ÷ 0.035.4 in.). A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed.
Page 305 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Headlight, tail light Headlight adjustment The headlamp features a twin bulb for low and high beam and a festoon bulb 9 __ for the city or parking light. When checking the proper aiming of the headlight beam: inflate tyres at the...
Page 306 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front headlamp bulb replacement Proceed as follows to reach the headlamp bulbs: - Undo the two upper screws (1); - lift the headlight assembly by releasing it from the lower clips (2);...
Page 307 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Headlight removal - Remove the tool as described in the relevant paragraph. - Remove all connectors. - Loosen the two front screws (1). H10505 - Unhook the clutch cable (2) from the fastening.
Page 308 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Turning indicator bulb replacement - Loosen the screw (1); H10509 - remove lens (2) and replace bulb (3) pushing it inside, and turning it to remove Once the bulb has been replaced, reverse the above procedure to reassemble.
Page 309 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Number plate bulb replacement - Loosen screw (1) and remove the number plate bulb (2) from the mudguard. H10510 - Extract the bulb holder (3) with the bulb (4) from the housing.
Page 310: Electrical System
ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Left-hand switch (MY12) MY12 High beam flashing light High beam switch control Low beam switch Left-hand turning indicators (self-cancelling) Right-hand turning indicators (self-cancelling) To deactivate the turning indicators, press the control lever after it is returned to the centre.
Page 311 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Left-hand switch (MY13) MY13 The left-hand handlebar switch contains the following commands: High beam flasher (self-cancelling). High beam switch. Low beam switch. Left-hand turning indicators. Right-hand turning indicators . To deactivate the turning indicators, press the control lever after it is returned to the centre.
Page 312 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Turn Switch= Turn Switch TURN SWITCH Premuto (OFF)= Pressed (OFF) Horn Switch= Horn Switch TIPO AZ/GR BL/B AZ/N A riposo (OFF)= At rest (OFF) STABILE Premuto (ON)= Pressed (ON) INSTABILE...
Page 313 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Right-hand switch removal - Remove the tool as described in the relevant paragraph. - Loosen the screws (1) and move the lever/master cylinder. H10514 - Disconnect the connector (2). H10515 - Loosen the front screw (3) and turn the switch (4);...
Page 314 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Left-hand switch removal - Remove the tool as described in the relevant paragraph. - Disconnect the two connectors (1) and (2). H10518 - Loosen the two screws (3) and remove the light switch (4).
Page 315 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Fuses • When you find a blown fuse, always investigate and eliminate the cause before replacing it. • Never replace a fuse with another fuse with a different rating. •...
Page 316 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Auxiliary fuses (3) 900 - 900R MY13 Located at the rear of the motorcycle under the saddle. Fuse 1 = 7.5. A Instrument panel Engine control Solenoid starter Diagnosis Fuse 2 = 15.
Page 317 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Semiconductor parts • Be careful to never drop parts that incorporate a semiconductor, such as the ECU or the voltage regulator/rectifier. • Closely follow the relevant instructions when inspecting these parts. An improper procedure may lead to severe damage.
Page 318 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Relay test Gain access to the relays as described in the relevant paragraph; then remove them. 1) Main relay. 2) Electric fan relay 3) Fuel pump relay H10525 A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation.
Page 319 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Combined dashboard H10526 The motorcycle has a combined dashboard divided into the following areas: 1. Warning lights (see “ Warning light description”). 2. Multifunction display (see “ Multifunction display description”).
Page 320 - Critical fault: the engine switches off and you must contact your HUSQ- VARNA dealer. - Fault with emergency operating: the engine operates with reduced performance to allow you to reach the nearest HUSQVARNA dealer to have the fault checked. “HAZARD” warning light (RED)
Page 321 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Multifunction display description 1. “ICE” indicator: This appears when the external temperature is lower than 3°C or 37.4°F 2. “SERVICE” indicator: This indicates that it is time for a service.
Page 322 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Setting units of measurement The units of measurement must be set when the motorcycle is stationary and the key is set to ON. - Press the “S” button (1) until the word “ODO” or “TEMP” appears on the display.
Page 323 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Setting parameters With the dashboard on, press the “S” button (1) to display the various display functions: ODO ; TRIP ; TEMP ; CON ; CLOCK The “ODO”, “TEMP” and “CLOCK” functions are for display purposes only.
Page 324 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Control unit removal - Remove the relay support as described in the relevant paragraph. - Lift the control unit (1) removing it from the guides. H10535 - Disconnect the connector (2) pressing with a screwdriver the tooth (3) and turning the locking element (4).
Page 325 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Ignition removal - Remove the relay support as described in the relevant paragraph. - Loosen the two screws (1) with the special wrench. - Lift the block (2) and disconnect the block connector (3) and the alarm system connector (4).
Page 326 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear stop microswitch replacement - Loosen the three screws (1). - Remove the spring (2) and remove the cover (3). - Loosen the three screws (4), remove the upper part (5.).
Page 327 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Front stop microswitch replacement - Remove the front fairing as described in the relevant paragraph. - Loosen the two screws (1) and remove the brake lever. - Lift the microswitch (2) to remove it.
Page 328 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Stand rotative switch replacement - Remove the fuel tank as described in the relevant paragraph. - Loosen the nut (1) and remove the switch (2) from the stand. - Remove the fastening from the harness (3).
Page 329 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Water temperature sensor replacement - Remove the reservoir and bleed the cooling system as described in the relevant paragraph. - Unhook the connector retainer (1) and remove the connector. - Loosen the sensor (2); replace and tighten it to torque (see Chapter F4).
Page 330 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Troubleshooting Charging system A battery that does not hold charge might be a symptom of: 1) current draw (see paragraph "Battery"); 2) incorrect voltage (see paragraph "Regulated voltage"); 3) no continuity in generator (see paragraph "Checking generator stator wind- ings resistance");...
Page 331 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Electrical connectors positioning In the front part above the light, the following connectors to be found: 1) Left-hand switch connectors. 2) Headlight connector . 3) Dashboard connector. 4) R.H. turning indicator connector.
Page 332 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 In the area below the saddle and above the filter box, the following connectors are to be found: 13) Air temperature sensor connector. 14) Fuel pump connector. 15.) Diagnosis connector.
Page 333 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 In the central area behind the cylinder block, the following connectors are to be found: 28) 12 volt plug connector. 29) Water temperature sensor connector. 30) Lambda sensor connector. 31) Stand rotative switch connector.
Page 334 ELECTRICAL SYSTEM NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Important Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches;...
Page 335 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 336 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Coolant level check ..................N.3 Coolant replacement ..................N.3 Cooling circuit ....................N.6 Servicing the engine cooling system ............N.7 Workshop Manual Ed. 11-2011...
Page 337 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Coolant level check When the engine is cold, check that the coolant level is between the two MIN and MAX marks on the expansion tank (1) on the right side of the vehicle.
Page 338 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Loosen the screw (2) of the lower pipe (3) that connects the radiator (4) to the exchanger (5). H10692 - Remove the exchanger pipe (3) and let the coolant drain in the bucket; during the reassembly, replace the seal (6).
Page 339 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 - Remove the radiator cap (9). - Loosen the coolant bleed valve (10) on the water pump cover and at the same time continue to pour liquid in the radiator until it comes out of the hole of the bleed valve, then tighten again the bleed valve (10).
Page 340 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Cooling circuit H10882 The forced circulation cooling system uses a centrifugal pump (located to the right of the cylinder head) and two downdraft radiators. Radiator cap Radiator Expansion tank Expansion tank cap...
Page 341 ENGINE COOLING NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Servicing the engine cooling system If the coolant runs too hot, check the radiators. Any foreign matter trapped be- tween the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected. If damage exceeds this limit, the radiator must be replaced.
Page 343 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose.
Page 344 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Torque Safety Tightening description Notes (Nm) tightening Battery to engine support Current plug to engine support 19.0 Battery to chassis support Exhaust valve actuator to battery support Sprocket cover to engine...
Page 345 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Torque Safety Tightening description Notes (Nm) tightening Reservoir support to small chassis Number plate light to number plate holder Number plate holder cover Passenger handle to number plate holder...
Page 346 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Torque Safety Tightening description Notes (Nm) tightening Front brake eyelet to bottom yoke Side stand switch Rear brake hose ring to swinging arm Chassis slider to swinging arm Lower handlebar clamps to steering head 38.0...
Page 347 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Torque Safety Sequences / further instructions Notes (Nm) tightening Engine to chassis Engine to chassis, front L.H. 66.0 step 1 Engine to chassis, central L.H. 38.0 step 2 Engine to chassis, lower L.H.
Page 348 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Torque Safety Tightening description (for ABS version only) MY13 Notes (Nm) tightening Speed sensor to fork ABS unit mount to frame Distributor to steering base ABS brake line / distributor...
Page 349 TIGHTENING TORQUE FIGURES NUDA 900 2012/2013 - NUDA 900 R 2012/2013 NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers 2 Nm 0.2 Kgm 1.45 ft/lb...
Page 351 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Section Workshop Manual Ed. 11-2011...
Page 352 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Sommario Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.3 Front wheel ....................Y.5 Removing the front wheel ................Y.7 Refitting the front wheel ................Y.8 Rear wheel ....................Y.10 Removing the rear wheel................
Page 353 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Chassis The chassis is a tubular steel trellis type with stainless steel removable rear small chassis. In case of violent shocks or accidents, if you think that the chassis might be bent or damaged, proceed with an im- mediate inspection and, if necessary, replace it.
Page 354 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 H10885 H10886 Workshop Manual Ed. 11-2011...
Page 355 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part. A ENGINE MOUNTING SCREWS B REAR CHASSIS MOUNTING SCREWS C FOOTREST-PINS-SPRINGS...
Page 356 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 MY13 H12059 1) Tyre 2) Rim 3) Bearings 4) Sealing rings 5) Inner spacer 6) Outer spacer 7) Wheel axle 8) Brake discs 9) Tone wheel Workshop Manual Ed. 11-2011...
Page 357 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. Loosen the screws (1) to remove the callipers.
Page 358 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Refitting the front wheel Refit the wheel (1) in the fork making sure that you position the spacer (2) on the left-hand side of the wheel. H10892 H10893 Insert the pin (3) and tighten it to torque.
Page 359 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Tighten the screws (4) to lock the pin (3) on the leg of the right-hand fork. H10894 Reinstall on both sides the callipers (5) and tighten the screws (6) to torque.
Page 360 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear wheel H10896 Tyre Inner spacer Bearings Elastic rings Sealing rings Outer spacer Phonic wheel Outer spacer 10) Cush drive dampers 11) Sprocket holder hub 12) Spacer 13) Sprocket 14) Brake Disc Workshop Manual Ed.
Page 361 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...
Page 362 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Wheel axle warpage Use a feeler gauge to check the pint out-of-round; if the value of the warpage REAR exceeds the max allowed limit, replace it. Axle runout over 100 mm...
Page 363 CHASSIS AND WHEELS NUDA 900 2012/2013 - NUDA 900 R 2012/2013 Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket. 1 Normal wear 2 Exceeding wear...

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Summary of Contents for Husqvarna NUDA 900 R 2012

Page 3: Workshop Manual

Page 15: General Information

Page 164: Crankcase Disassembly

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