Husqvarna F2101 Manuals

Manuals and User Guides for Husqvarna F2101. We have 1 Husqvarna F2101 manual available for free PDF download: Repair Manual

Husqvarna F2101 Repair Manual (310 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 79.36 MB

Table of Contents
4
Removing the Clutch Cover
6
Removing the Clutch Discs
6
Means of Representation
9
Symbols Used
9
Formats Used
9
Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
Important Notes
11
Manufacturer and Implied Warranty
11
Operating and Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
Serial Numbers
12
Chassis Number
12
Type Label
12
Engine Number
12
Fork Article Number
12
Shock Absorber Article Number
13
Motorcycle
14
Raising the Motorcycle with a Lift Stand
14
Removing the Motorcycle from the Lift Stand
14
Starting the Vehicle
14
Starting the Motorcycle to Check the Function
15
Fork, Triple Clamp
16
Adjusting the Compression Damping of the Fork
16
Adjusting the Rebound Damping of the Fork
16
Bleeding the Fork Legs
17
Cleaning the Dust Boots of the Fork Legs
17
Removing the Fork Legs
18
Installing the Fork Legs
18
Removing the Fork Protector
19
Installing the Fork Protector
19
Performing a Fork Service
20
Disassembling the Fork Legs
20
Removing the Spring
22
Disassembling the Cartridge
23
Disassembling the Piston Rod
24
Disassembling the Hydrostop Unit
26
Disassembling the Seal Ring Retainer
26
Checking the Fork Legs
27
Assembling the Seal Ring Retainer
28
Assembling the Hydrostop Unit
29
Piston Rod, Assembling
29
Cartridge, Assembling
31
Assembling the Fork Legs
32
Lubricating the Steering Head Bearing
37
Removing the Lower Triple Clamp
37
Installing the Lower Triple Clamp
38
Checking the Steering Head Bearing Play
40
Changing the Steering Head Bearing
41
Adjusting the Steering Head Bearing Play
42
7 Handlebar,Controls
44
Handlebar Position
44
Adjusting the Handlebar Position
44
Adjusting the Basic Position of the Clutch Lever
45
Checking the Rubber Grips
45
Checking the Throttle Cable Routing
45
Checking the Play in the Throttle Cable
46
Adjusting the Play in the Throttle Cable
47
Setting the Characteristic Map of the Throttle Response
48
Frame
50
Checking the Frame
50
Changing the Footrests
50
Shock Absorber, Swingarm
52
Adjusting the High-Speed Compression Damping of the Shock Absorber
52
Adjusting the Low-Speed Compression Damping of the Shock Absorber
52
The Shock Absorber
53
Measuring the Rear Wheel Sag Unloaded
54
Checking the Static Sag of the Shock Absorber
54
Checking the Riding Sag of the Shock Absorber
55
Shock Absorber
55
Adjusting the Riding Sag
56
Removing the Shock Absorber
57
Installing the Shock Absorber
59
Checking the Shock Absorber Linkage
60
Servicing the Shock Absorber
62
Removing the Spring
63
Disassembling the Damper
64
Disassembling the Piston Rod
65
Disassembling the Seal Ring Retainer
66
Changing the Pilot Bushing
67
Checking the Damper
68
Removing the Heim Joint
69
Installing the Heim Joint
70
Assembling Seal Ring Retainer
71
Assembling the Piston Rod
71
Assembling the Damper
73
Bleeding and Filling the Damper
75
Filling the Damper with Nitrogen
79
Installing the Spring
80
Checking the Swingarm
81
Checking the Swingarm Bearing for 14.6.1 Play
81
Removing the Swingarm
82
Installing the Swingarm
83
Changing the Swingarm Bearing
85
10 Exhaust
88
Removing the Manifold
88
Installing the Manifold
89
Removing the Main Silencer
90
Installing the Main Silencer
90
Changing the Glass Fiber Yarn Filling of the Main Silencer
91
11 Air Filter
92
Removing the Air Filter Box Cover
92
Installing the Air Filter Box Cover
92
Removing the Air Filter
92
Installing the Air Filter
93
Cleaning the Air Filter and Air Filter Box
93
Sealing the Air Filter Box
94
Fuel Tank, Seat, Trim
95
Opening the Filler Cap
95
Closing the Filler Cap
95
Removing the Right Side Cover
96
Installing the Right Side Cover
96
Removing the Seat
96
Mounting the Seat
97
Removing the Fuel Tank
98
Installing the Fuel Tank
99
Checking the Fuel Pressure
101
Changing the Fuel Pump
102
Changing the Fuel Filter
104
Changing the Fuel Screen
108
13 Mask, Fender
110
Removing Front Fender
110
Installing Front Fender
110
Removing the Start Number Plate
111
Installing the Start Number Plate
111
14 Wheels
112
Checking the Tire Air Pressure
112
Checking the Tire Condition
112
Checking the Wheel Bearing for Play
113
Checking the Brake Discs
113
Checking Spoke Tension
114
Front Wheel
114
Removing the Front Wheel
114
Installing the Front Wheel
115
Changing the Front Brake Disc
116
Changing Front Wheel Bearing
117
Rear Wheel
118
Removing the Rear Wheel
118
Installing the Rear Wheel
119
Changing the Rear Brake Disc
120
Checking the Chain Tension
121
Adjusting the Chain Tension
121
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
122
Checking for Chain Dirt Accumulation
125
Cleaning the Chain
125
Changing the Drivetrain Kit
125
Changing the Rear Wheel Bearing
127
15 Wiring Harness, Battery
130
Changing the Main Fuse
130
Removing the Battery
131
Installing the Battery
132
Recharging the Battery
132
Checking the Charging Voltage
134
Checking the Open-Circuit Current
134
Checking the Capacitor
135
Checking the Starter Relay
136
Brake System
137
Checking the Front Brake Linings
137
Changing the Front Brake Linings
137
Hand Brake Lever
139
Checking the Front Brake Fluid Level
140
Adding Front Brake Fluid
141
Changing the Front Brake Fluid
142
Checking the Brake Linings of the Rear Brake
144
Changing the Rear Brake Linings
144
Brake Lever
146
Adjusting the Basic Position of the Foot Brake Lever
147
Checking the Rear Brake Fluid Level
147
Adding Rear Brake Fluid
148
Changing the Rear Brake Fluid
149
17 Engine
152
Removing the Engine
152
Installing the Engine
159
Engine Disassembly
167
Preparations
167
Removing the Clutch Push Rod
167
Draining the Engine Oil
167
Removing the Oil Filter
168
Gear Position Sensor, Removing
169
Removing the Spark Plug
169
Removing the Valve Cover
169
Starter Motor, Removing
170
Positioning the Engine at Ignition Top Dead Center
171
Removing the Timing Chain Tensioner
171
Removing the Camshafts
172
Cylinder Head, Removing
172
Removing the Piston
173
Rotor, Removing
173
Starter Drive, Removing
174
Removing the Suction Pump
174
17.3.17 Water Pump Impeller, Removing
175
Removing the Clutch Basket
177
Primary Gear, Removing
178
Timing Chain, Removing
178
Removing the Force Pump
178
Removing the Locking Lever
179
Shift Drum Locating Unit, Removing
180
Shift Shaft, Removing
180
17.3.27 Spacer, Removing
180
Left Engine Case, Removing
180
Shift Rails, Removing
181
Removing the Shift Drum
181
Shift Forks, Removing
182
Removing the Transmission Shafts
182
Removing the Crankshaft
182
Working on Individual Parts
183
Working on the Right Section of the Engine Case
183
Working on the Left Section of the Engine Case
185
Work on the Clutch Cover
186
Checking the Oil Pressure Regulator Valve
188
Checking the Lubrication System
189
Removing the Crankshaft Bearing Inner Race
189
Installing the Crankshaft Bearing Inner Race
190
Connecting Rod, Conrod Bearing, and Crank Pin, Changing
190
Checking the Crankshaft Run-Out at the Bearing Pin
192
Measuring the Crankshaft End Play
193
Removing the Drive Wheel of the Balancer Shaft
193
Installing the Drive Wheel of the Balancer Shaft
194
Cylinder - Nikasil ® Coating
194
Checking/Measuring the Cylinder
194
17 .4.15 Piston, Checking/Measuring
195
Measuring the Piston/Cylinder Mounting Clearance
196
Checking the Piston Ring End Gap
196
Camshafts, Checking
197
Checking the Pivot Points of the Camshafts
197
Valves, Removing
198
Valves, Checking
199
Valve Springs, Checking
200
Checking the Valve Spring Seat
200
Checking the Cam Levers
200
Checking the Cylinder Head
201
Valves, Installing
201
Checking the Freewheel
202
17.4.28 Freewheel, Removing
203
Freewheel, Installing
203
Checking the Electric Starter Drive
204
Checking the Timing Assembly
205
Preparing the Timing Chain Tensioner for Installation
206
Checking the Clutch
207
17.4.34 Shift Mechanism, Checking
208
Preassembling the Shift Shaft
209
Main Shaft, Disassembling
210
Disassembling the Countershaft
211
Transmission, Checking
211
Main Shaft, Assembling
213
Countershaft, Assembling
214
Engine Assembly
215
Installing the Crankshaft
215
Installing the Transmission Shafts
215
Shift Forks, Installing
216
Installing the Shift Drum
216
Shift Rails, Installing
216
Left Engine Case, Installing
217
Installing the Spacer
218
Shift Shaft, Installing
218
Shift Drum Locating Unit, Installing
218
Locking Lever, Installing
218
Installing the Force Pump
219
Installing the Suction Pump
220
Installing the Timing Chain
221
Installing the Primary Gear
221
Installing the Clutch Basket
222
Installing the Clutch Discs
223
Installing the Clutch Cover
223
Water Pump Cover, Installing
224
Starter Drive, Installing
225
Installing the Rotor and Ignition Pulse Generator
226
Installing the Piston
226
Cylinder Head, Installing
228
Installing the Camshafts
229
Installing the Timing Chain Tensioner
229
Checking the Valve Clearance
230
Adjusting the Valve Clearance
231
Installing the Starter Motor
232
Installing the Valve Cover
233
Spark Plug, Installing
234
Gear Position Sensor, Installing
234
Installing the Oil Filter
234
Installing the Oil Screen
235
Installing the Clutch Push Rod
236
Removing the Engine from the Engine Assembly Stand
236
18 Clutch
237
Checking/Correcting the Fluid Level of the Hydraulic Clutch
237
Changing the Hydraulic Clutch Fluid
238
19 Water Pump, Cooling System
240
Cooling System
240
Checking the Antifreeze and Coolant Level
240
Checking the Coolant Level
241
Draining the Coolant
242
Refilling with Coolant
242
Lubrication System
244
Oil Circuit
244
Checking the Engine Oil Level
244
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
245
Adding Engine Oil
248
Checking the Engine Oil Pressure
248
Ignition System
251
Ignition Coil - Checking the Secondary Winding
251
Checking the Spark Plug Connector
251
Alternator - Checking the Stator Winding
251
Removing the Stator and Crankshaft Position Sensor
252
Installing the Stator and Ignition Pulse Generator
252
22 Cylinder Head
254
Checking the Valve Clearance
254
Adjusting the Valve Clearance
257
23 Electric Starter
258
Checking the Starter Motor
258
24 Throttle Valve Body
259
Adjusting the Idle Speed
259
Executing the Initialization Run
259
25 Technical Data
261
Engine
261
Tolerance, Engine Wear Limits
262
Engine Tightening Torques
263
Capacities
265
Engine Oil
265
Coolant
265
Fuel
265
Chassis
265
Electrical System
266
Tires
266
Fork
266
Shock Absorber
267
Chassis Tightening Torques
267
26 Cleaning/Protective Treatment
270
Cleaning the Motorcycle
270
27 Storage
272
Putting into Operation after Storage
273
28 Service Schedule
274
Additional Information
274
Required Work
274
Recommended Work
275
29 Wiring Diagram
277
30 Substances
282
Auxiliary Substances
284
32 Special Tools
286
Standards
303
34 List of Abbreviations
304
Index
305

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