Table Of Contents - Husqvarna NUDA 900 R 2012 Workshop Manual

Table of Contents

Revision Record2
Foreword, Table Of Contents3
Workshop Manual3
Useful Tips4
Table Of Contents5
Important Notices7
General Safety Warnings8
Carbon Monoxide8
Parts Of The Vehicle That Become Hot8
Brake Fluid Safety Precautions8
Battery Safety Precautions9
Recommended Shop Practices10
General Information11
Technical Data13
Timing System13
Lubrication13
Ignition13
Fuel System13
Primary Drive13
Clutch13
Transmission13
Secondary Drive14
Chassis14
Front Suspension14
Rear Suspension14
Front Brake14
Rear Brake15
Rims15
Tyres15
Weight, Capacity15
Electrical Components Location16
The Electrical System Includes The Following Elements...16
Dimensions17
Maintenance19
Scheduled Maintenance Chart20
Troubleshooting23
Engine Troubleshooting24
Chassis Troubleshooting30
Electrical System Troubleshooting31
Settings And Adjustments33
Saddle Removal35
Central Cover Removal36
Side Panel Removal37
Throttle Cable Adjustment37
Throttle Control38
Throttle Position Adjustment38
Front Brake Control38
Position Adjustment38
Front Brake Lever Adjustment And Fluid Level Check39
Position Of The Clutch Control Adjustment40
Clutch Control Lever Distance Adjustment40
Clutch Free Play Adjustment41
Rear Brake Pedal Free Play Adjustment41
Rear Brake Fluid Level Check42
Oil Level Check42
Engine Oil Replacement And Cartridge Filter Replacement43
Coolant Level Check44
Coolant Replacement44
Air Filter Check47
Chain Adjustment48
Lubricating The Chain49
Suspension Settings Summary Tables50
Rear Shock Absorber52
Spring Preload Adjustment Nuda 90053
Spring Preload Adjustment Nuda 900 R54
Adjustment Shock Absorber Length Nuda 900 R55
Shock Absorber Hydraulic Damping Adjustment56
Fork Adjustment Nuda 90057
Fork Adjustment Nuda 900 R57
Fuel Supply Hose Inspection And Replacement58
Exhaust System Check59
Idle Speed Adjustment59
General Procedures61
Stand Removal / Replacement63
Stand Foot Replacement64
To Remove The Saddle65
Air-Box Cover Removal66
Side Panels Removal67
Number Plate Holder Removal67
Tail Light Removal69
Rear Turning Indicator Removal70
Tail Removal73
Front Fairing Removal74
Front Turning Indicator Removal75
Combined Dashboard Removal76
Front Mudguard Removal77
Front Mudguard Fin Removal78
Battery Removal79
Reservoir Removal80
Fuel Pump Removal82
Fuel Pump Inspection83
Filter Box Removal84
Throttle Body Removal86
Exhaust System Removal87
Lambda Sensor Removal90
To Remove Spark Plug91
Coil / Stick-Coil Removal And Spark Plug Test91
Horn Removal92
Radiator Removal92
Electric Fan Removal94
Gearbox Lever Removal94
Battery Housing Removal95
Engine Removal97
Engine Reassembly100
Engine Settings And Adjustments104
Valve Clearance Check105
Checking Cylinder "1" Valve Clearance105
Valve Clearance Measurement105
Checking Cylinder "2" Valve Clearance105
Half-Ball Replacement106
Locking The Crankshaft106
Chain Tensioner Disassembly107
Camshaft Mount Disassembly107
Camshaft Removal107
Camshaft Assembly108
Exhaust Camshaft Installation108
Intake Camshaft Installation108
Camshaft Mount Assembly109
Timing Check111
Engine Phasing112
Disassembly Of The Chain Tensioner112
Assembly Of The Camshaft Mount113
General Engine Procedures115
Left Clutch Side Cover Removal/Installation117
Gearbox Lever Removal/Installation117
Oil Dipstick Removal117
Cover Removal117
Gearbox Selector Shaft Oil Seal Removal/Installation118
Clutch Disengagement Shaft Oil Seal Removal118
Clutch Disengagement Shaft Oil Seal Installation119
Clutch Disengagement Shaft Upper Bearing Removal119
Installation Of Both Clutch Disengagement Shaft Bearings119
Disengagement Shaft Installation119
Left Engine Crankcase Cover Assembly120
Tightening Sequence Of The Left Engine Crankcase Cover120
Oil Dipstick Installation120
Right Engine Crankcase Removal/Replacement121
Stator Disassembly121
Stator Assembly121
Right Engine Crankcase Cover Installation122
Tightening Sequence Of The Right Engine Crankcase Cover122
Flywheel And Starter Motor Idle Gear Removal123
Removal/Installation Of The Freewheel From/On The Flywheel123
Freewheel Control Gear Removal123
Starter Motor Idle Gear Removal/Installation124
Installation Of The Flywheel With Freewheel Control Gear124
Crankshaft Position Sensor Removal/Installation125
Chain Sprocket Removal/Installation125
Starter Motor Removal/Installation126
Gear Position Sensor Removal/Installation127
Removal/Installation Of The Complete Clutch128
Clutch Pressure Plate Disassembly131
Oil Pump132
Oil Suction Pump Removal/Installation132
Oil Force Pump Removal/Installation133
Oil Pump Shaft Disassembly134
Coolant Pump Removal/Installation135
Coolant Pump Control Gear Removal/Installation138
Oil Sump Removal/Installation140
Mesh Oil Filter Replacement140
Swing Arm Cover Removal/Installation141
Oil Pressure Adjustment Valve Check/Replacement142
Timing Chain Removal/Replacement (Engine Removal)143
Heat Exchanger Removal/Installation145
Cylinder Head Removal/Disassembly147
Removal Of The Ignition Coil From The Spark Plug Recess149
Cylinder Head Cover Removal/Installation149
Chain Tensioner Removal/Installation150
Lock The Crankshaft151
Crankshaft Locking Screw Removal151
Disassembly And Assembly Of The Camshaft Mount152
Camshaft Removal/Replacement154
Timing Chain Slider Replacement156
Rocker Arm Removal/Installation Or Replacement157
Cylinder Head Removal/Installation - Replacement Of Cylinder Head Gasket158
Cylinder Head Disassembly159
Valve Removal159
Crankcase Disassembly163
Gearbox Removal166
Gearbox Output Shaft Disassembly167
Gearbox Input Shaft Disassembly169
Shift Drum Star Removal170
Ratchet Removal170
Gearbox Fork Removal170
Gear Selection Drum Removal171
Gear Selection Drum Disassembly171
Crankshaft Removal172
Compensation Arm Removal172
Connecting Rod Cap Removal172
Main Bearing Cap Removal173
Main Split Bearing Removal174
Chain Tensioner Slider Removal174
Piston Removal174
Piston Ring Removal175
Piston Ring Assembly175
Piston Installation176
Installing The Pistons With The Connecting Rod176
Chain Tensioning Slider Installation177
Main Split Bearing Installation177
Crankshaft Installation177
Main Bearing Cap Installation178
Connecting Rod Cap Installation178
Compensation Arm Installation179
Gear Selector Drum Installation180
Installation Of The 5Th/6The Gear Engagement Fork180
Installation Of The 1St/3Rd And 2Nd/4Th Gear Engagement Fork180
Ratchet Installation180
St /3 Rd And 2 Nd /4 Th Gear Engagement Fork180
Star-Shaped Stop Element Installation181
Reassembly Of The Gearbox Input And Output Shaft181
Installation Of The Lower Part Of The Engine Crankcase Half182
Fixing The Compensation Arm184
Fixing The Crankcase Halves184
Gearbox Output Shaft Oil Seal Installation185
Engine Torque Figures187
Wear Limits Of Engine Parts201
Engine Wear Value Table203
Crankshaft / Casing Assy203
Connecting Rod203
Compensation Connecting Rod Compensation Arm203
Gearbox204
Gear Shift Control205
Piston206
Piston Pin207
Cylinders / Casing Assy207
Timing Chain207
Head207
Valves208
Oil Pump (Engine Wear Value Table)209
Starting Device209
Spark Plug209
Front End Exploded Diagram213
Front End Disassembly214
Front End Assembly216
Suspension Settings - Summary Tables218
Servicing Forks220
Bushings And Seals Replacement223
Assembly224
Servicing Of The Damper225
Damper Reassembly227
Rear Shock Absorber Removal233
Rear Shock Absorber Spring Replacement234
Mudguard / Chain Guard Removal236
Sprocket Casing Removal237
Rear Swinging Arm Removal238
Chain Upper Slide Removal239
Chain Lower Slide Removal240
Brakes: Non-Abs Version - My12 Only241
Braking System243
Brake Disc245
Rear Braking System Removal246
Front Braking System Removal248
Rear Pads Disassembly250
Rear Pads Assembly250
Checking Brake Pads For Wear / Replacing The Pads250
Replacing Front Brake Pads Nuda 900251
Front Brake Pad Replacement - Nuda 900 R252
Brake Fluid Replacement253
Fluid Replacement And System Bleeding253
Front Braking System253
Rear Braking System254
Bleeding The Front Braking System255
Bleeding The Rear Braking System257
Brakes: Abs Version My13 Only259
Braking System (Abs)261
Abs Circuit Diagram261
Brake Disc Checks264
Removing The Braking System265
Replacing A Brake Line266
Diagram Of Location Of Lines266
Removal Of The Front Braking System268
Removing The Front Brake Calliper268
Removing The Front Master Cylinder269
Removing The Rear Braking System269
Removing The Rear Master Cylinder270
Removing The Rear Brake Calliper271
To Replace Brake Fluid275
Fluid Replacement, System Bleeding275
Changing The Front Braking System Fluid275
Changing The Rear Braking System Fluid276
Bleed The Front Braking System277
Bleed The Rear Braking System279
Electrical System281
Wiring Diagram My12285
Key To Wiring Diagram My12287
Wiring Diagram My13289
Key To Wiring Diagram My13291
Electrical Component Location292
Checking Generator Stator Windings Resistance296
Generator Performance296
Gear Position Sensor297
Crankshaft Position Sensor297
Ignition And Injection System298
Charging System299
Charging System Inspections300
Battery Inspection300
Voltage Regulator Inspection300
Voltage Regulator/Rectifier Wiring Diagram300
Regulated Voltage300
Electric Starting System301
Starting System Inspection302
Solenoid Starter Inspection302
Starter Relay Wiring Diagram302
Starter Motor Inspection302
Starter Motor302
Coil Windings / Stick-Coil Inspection303
Electronic Control Unit (Ecu)303
Spark Plug Inspection304
Battery Charger304
Headlight, Tail Light305
Headlight Adjustment305
Front Headlamp Bulb Replacement306
Headlight Removal307
Turning Indicator Bulb Replacement308
Tail Light Replacement308
Number Plate Bulb Replacement309
Left-Hand Switch (My12)310
Left-Hand Switch - (My12)311
Right-Hand Switch312
Right-Hand Switch Removal313
Left-Hand Switch Removal314
General Fuse 30A315
Auxiliary Fuses 900 - 900R My12315
Auxiliary Fuses 900 - 900R My13316
Semiconductor Parts317
Relay Removal317
Relay Test318
Combined Dashboard319
Warning Light Description320
Multifunction Display Description321
Clock Adjustment321
Setting Units Of Measurement322
Setting Parameters323
Trip Function323
Con Function323
Changing Ecu Mapping323
Control Unit Removal324
Ignition Removal325
Combined Dashboard Replacement325
Rear Stop Microswitch Replacement326
Front Stop Microswitch Replacement327
Speed Sensor Replacement327
Stand Rotative Switch Replacement328
12V Plug Replacement328
Water Temperature Sensor Replacement329
Starting System330
Electronic Ignition System330
Electrical Connectors Positioning331
Before Washing The Motorcycle334
Important334
Engine Cooling335
Checking Coolant Level337
To Replace Coolant337
Cooling Circuit340
Servicing The Engine Cooling System341
Tightening Torque Figures343
Standard Torque Values For The Different Thread Sizes349
Chassis And Wheels351
Lubrication Points (Lubricant)353
Front Wheel Exploded View355
Removing The Front Wheel357
Refitting The Front Wheel358
Rear Wheel Exploded View360
Removing The Rear Wheel361
Wheel Axle Warpage362
Axle Runout Over 100 Mm362
Wheel Rim Warpage362
Rear Chain Sprocket, Secondary Drive Sprocket And Chain363
Checking Sprocket Wear363