Husqvarna F2101Q1 Manuals

Manuals and User Guides for Husqvarna F2101Q1. We have 1 Husqvarna F2101Q1 manual available for free PDF download: Repair Manual

Husqvarna F2101Q1 Repair Manual (321 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 83.71 MB

Table of Contents
4
Chassis Tightening Torques
6
Means of Representation 1
9
Symbols Used
9
Formats Used
9
Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
Important Notes 3
11
Manufacturer and Implied Warranty
11
Fuel, Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
Serial Numbers
12
Vehicle Identification 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 8 Function
15
Fork, Triple Clamp
16
Air Suspension AER 48
16
Checking the Basic Setting of the Fork
16
Adjusting the Fork Air Pressure
17
Adjusting the Compression Damping of the Fork
18
Adjusting the Rebound Damping of the Fork
18
Bleeding the Fork Legs
19
Cleaning the Dust Boots of the Fork Legs
19
Removing the Fork Legs
20
Installing the Fork Legs
21
Removing the Fork Protector
21
Installing the Fork Protector
22
Servicing the Fork
22
Disassembling the Fork Legs
23
Disassembling the Air Cartridge
27
Disassembling the Shock Absorber Cartridge
28
Checking the Fork Legs
30
Assembling the Shock Absorber Cartridge
31
Assembling the Air Cartridge
33
Assembling the Fork Legs
35
Lubricating the Steering Head Bearing
41
Removing the Lower Triple Clamp
41
Installing the Lower Triple Clamp
42
Checking Steering Head Bearing Play
44
Changing the Steering Head Bearing
45
Adjusting Steering Head Bearing Play
46
7 Handlebar,Controls
48
Handlebar Position
48
Adjusting the Handlebar Position
48
Clutch Lever
49
Checking the Rubber Grips
49
Checking Throttle Cable Routing
50
Checking Throttle Cable Play
50
Adjusting Throttle Cable Play
51
Setting the Characteristic Map of the Throttle Response
52
Frame
54
Checking the Frame
54
Changing the Footrests
54
Shock Absorber, Link Fork
56
Adjusting the High-Speed Compression Damping of the Shock Absorber
56
Adjusting the Low-Speed Compression Damping of the Shock Absorber
56
Adjusting the Rebound Damping of the Shock Absorber
57
Measuring the Rear Wheel Dimension Unloaded
58
Checking the Static Sag of the Shock Absorber
58
Checking the Riding Sag of the Shock Absorber
59
Shock Absorber
59
Adjusting the Riding Sag
60
Removing the Shock Absorber
61
Installing the Shock Absorber
62
Checking the Shock Absorber Linkage
64
Servicing the Shock Absorber
66
Removing the Spring
67
Disassembling the Damper
68
Disassembling the Piston Rod
69
Disassembling the Seal Ring Retainer
70
Changing the Pilot Bushing
71
Checking the Damper
72
Removing the Heim Joint
73
Installing the Heim Joint
74
Assembling Seal Ring Retainer
74
Assembling the Piston Rod
75
Assembling the Damper
77
Bleeding and Filling the Damper
79
Filling Damper with Nitrogen
82
Installing the Spring
83
Checking the Link Fork
84
Checking the Fork Bearing for Play
84
Removing the Link Fork
85
Installing the Link Fork
86
Changing the Fork Bearing
88
Changing the Heim Joint
90
Checking the Heim Joint for Play
92
Exhaust System
93
Removing the Manifold
93
Installing the Manifold
94
Removing the Main Silencer
95
Installing the Main Silencer
95
Changing the Glass Fiber Yarn Filling of the Main Silencer
96
Air Filter 11
97
Removing the Air Filter Box Cover
97
Installing the Air Filter Box Cover
97
Removing the Air Filter
97
Installing the Air Filter
98
Cleaning the Air Filter and Air Filter Box
98
Sealing the Air Filter Box
99
12 Fuel Tank, Seat, Trim
100
Opening Fuel Tank Filler Cap
100
Closing the Fuel Tank Filler Cap
100
Removing the Right Side Cover
101
Installing the Right Side Cover
101
Removing the Seat
101
Mounting the Seat
102
Mount and Tighten Screw
102
Guideline
102
Removing the Fuel Tank
103
Installing the Fuel Tank
104
Remaining Screws, M5
105
Checking the Fuel Pressure
106
Changing the Fuel Pump
107
Changing the Fuel Filter
110
Changing the Fuel Screen
113
Mask, Fender 13
115
Removing Front Fender
115
Installing Front Fender
115
Removing the Start Number Plate
116
Installing the Start Number Plate
116
Wheels 14
117
Checking Tire Pressure
117
Checking the Tire Condition
117
Checking the Wheel Bearing for Play
118
Checking the Brake Discs
118
Checking Spoke Tension
119
Checking the Rim Run-Out
119
Frontwheel
120
Removing the Front Wheel
120
Installing the Front Wheel
121
Changing the Front Brake Disc
122
Changing the Front Wheel Bearing
122
Rear Wheel
124
Removing the Rear Wheel
124
Installing the Rear Wheel
125
Changing the Rear Brake Disc
126
Checking the Chain Tension
126
Adjusting the Chain Tension
127
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
127
Checking for Chain Dirt Accumulation
130
Cleaning the Chain
130
Changing the Drivetrain Kit
131
Preparatory Work Remove the Air Filter Box Cover
131
Changing the Rear Wheel Bearing
133
Wiring Harness, Battery 15
135
Changing the Main Fuse
135
Of the 12 V Battery
136
Connecting the Negative Cable of the 12 V Battery
136
Removing the 12 V Battery
137
Installing the 12 V Battery
138
Charging the 12 V Battery
138
Checking the Charging Voltage
140
Checking the Open-Circuit Current
140
Checking the Capacitor
141
Checking the Starter Relay
142
Brake System 16
143
Checking the Front Brake Linings
143
Changing the Front Brake Linings
143
Hand Brake Lever
145
Checking the Front Brake Fluid Level
146
Adding Front Brake Fluid
146
Changing the Front Brake Fluid
148
Checking the Brake Linings of the Rear Brake
150
Changing the Rear Brake Linings
150
Checking the Free Travel of Foot
152
Brake Lever
152
Adjusting the Basic Position of the Foot Brake Lever
152
Checking the Rear Brake Fluid Level
153
Adding Rear Brake Fluid
153
Changing the Rear Brake Fluid
155
Engine 17
157
Removing the Engine
157
Installing the Engine
164
Engine Disassembly
172
Preparations
172
Removing the Clutch Push Rod
172
Draining the Engine Oil
172
Removing the Oil Filter
173
Gear Position Sensor, Removing
173
Removing the Spark Plug
174
Removing the Valve Cover
174
Starter Motor, Removing
175
Positioning the Engine at Ignition Top Dead Center
175
Cylinder Head, Removing
177
Removing the Piston
177
Removing the Rotor
178
Starter Drive, Removing
178
Removing the Suction Pump
179
17.3.17 Water Pump Impeller, Removing
180
Removing the Clutch Cover
180
Removing the Clutch Discs
181
Removing the Clutch Basket
181
Removing the Primary Gear Wheel
182
Timing Chain, Removing
182
Removing the Force Pump
183
Removing the Locking Lever
183
Shift Drum Locating Unit, Removing
184
Removing the Shift Shaft
184
17.3.27 Spacer, Removing
184
Removing the Left Engine Case
184
Shift Rails, Removing
185
Removing the Shift Drum
185
Removing the Shift Forks
186
Removing the Transmission Shafts
186
Removing the Crankshaft
186
Working on Individual Parts
187
Working on the Right Section of the Engine Case
187
Working on the Left Section of the Engine Case
189
Work on the Clutch Cover
190
Checking the Oil Pressure
192
Control Valve
192
Checking the Lubrication System
193
Removing the Crankshaft Bearing Inner Race
193
Installing the Crankshaft Bearing Inner Race
194
Connecting Rod, Conrod Bearing, and Crank Pin, Changing
194
Checking the Crankshaft Run-Out at the Bearing Pin
196
Measuring the Crankshaft End Play
197
Removing the Drive Gear Wheel of the Balancer Shaft
197
Installing the Drive Gear Wheel of the Balancer Shaft
198
Cylinder- Nikasil ® Coating
198
17.4.14 Checking/Measuring the Cylinder
198
Checking/Measuring the Piston
199
Measuring the Piston/Cylinder Mounting Clearance
200
Checking the Piston Ring End Gap
200
Camshafts, Checking
201
Checking the Pivot Points of the Camshafts
201
Valves, Removing
202
Valves, Checking
203
Valve Springs, Checking
203
Checking the Valve Spring Seat
204
Checking the Cam Levers
204
Checking the Cylinder Head
204
Installing the Valves
205
Checking the Freewheel
206
Freewheel, Removing
206
Freewheel, Installing
207
Checking the Electric Starter Drive
208
Checking the Timing Assembly
209
Preparing the Timing Chain Tensioner for Installation
210
Checking the Clutch
211
Checking the Shift Mechanism
212
Preassembling the Shift Shaft
213
Disassembling the Main Shaft
214
Disassembling the Countershaft
215
Checking the Transmission
215
Assembling the Main Shaft
217
Assembling the Countershaft
218
Engine Assembly
219
Installing the Crankshaft
219
Installing the Transmission Shafts
219
Shift Forks, Installing
220
Installing the Shift Drum
220
Shift Rails, Installing
220
Left Engine Case, Installing
221
Installing the Spacer
221
Shift Shaft, Installing
222
Shift Drum Locating Unit, Installing
222
Locking Lever, Installing
222
Installing the Force Pump
222
Installing the Suction Pump
223
Installing the Timing Chain
224
Installing the Primary Gear Wheel
225
Installing the Clutch Basket
225
Installing the Clutch Discs
226
Installing the Clutch Cover
227
Water Pump Cover, Installing
228
Starter Drive, Installing
229
Installing the Rotor
229
Installing the Piston
229
Installing the Cylinder Head
231
Installing the Camshafts
232
Installing the Timing Chain Tensioner
233
Checking the Valve Clearance
233
Adjusting the Valve Clearance
234
Installing the Starter Motor
235
Installing the Valve Cover
235
Spark Plug, Installing
236
Gear Position Sensor, Installing
236
Installing the Oil Filter
237
Installing the Oil Screen
237
Installing the Clutch Push Rod
238
Removing the Engine from the Engine Assembly Stand
238
Clutch
239
Checking/Correcting the Fluid Level of the Hydraulic Clutch
239
Changing the Hydraulic Clutch Fluid
240
Checking the Clutch
241
19 Water Pump, Cooling System
248
Cooling System
248
Checking the Antifreeze and Coolant Level
248
Checking the Coolant Level
249
Draining the Coolant
250
Refilling with Coolant
250
Lubrication System
252
Oil Circuit
252
Checking the Engine Oil Level
252
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
253
Adding Engine Oil
256
Checking the Oil Pressure
257
Ignition System
259
Ignition Coil - Checking the Secondary Winding
259
Connector
259
Alternator - Checking the Stator Winding
259
Crankshaft Speed Sensor
260
Speed Sensor
260
Changing the Spark Plug
261
Cylinder Head 22
263
Checking the Valve Clearance
263
Adjusting the Valve Clearance
266
Electric Starter System
267
Checking the Starter Motor
267
24 Throttle Valve Body
268
Adjusting the Idle Speed
268
Performing the Initialization Run
268
25 Technical Data
270
Engine
270
Tolerance, Engine Wear Limits
271
Engine Tightening Torques
272
Capacities
274
Engine Oil
274
Coolant
274
Fuel
274
Chassis
274
Electrical System
275
Tires
275
Fork
275
Shock Absorber
276
Cleaning/Protective Treatment
279
Cleaning the Motorcycle
279
Storage 27
281
Putting into Operation after Storage
282
Service Schedule 28
283
Additional Information
283
Required Work
283
Recommended Work
284
Wiring Diagram 29
287
30 Substances
292
Auxiliary Substances
294
32 Special Tools
296
33 Standards
314
List of Abbreviations 34
315
Index
316

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