Husqvarna 2011 SMS 630 Manuals

Manuals and User Guides for Husqvarna 2011 SMS 630. We have 1 Husqvarna 2011 SMS 630 manual available for free PDF download: Workshop Manual

Husqvarna 2011 SMS 630 Workshop Manual

Husqvarna 2011 SMS 630 Workshop Manual (455 pages)

TE 630 / 2011 I.E. SMS 630 / 2011 I.E.

Brand: Husqvarna | Category: Motorcycle | Size: 31.52 MB

Table of Contents

Table of Contents

5
- Foreword, Table of Contents
  3
  - Workshop Manual
    3
  - Table of Contents
    5
- Important Notices
  7
- General Information
  9
Table of Contents

10
- Cooling
  11
- Drive and Transmission
  11
- Engine
  11
- Fuel System
  11
- Ignition System
  11
- Lubrication
  11
- Part. N. 8000 H2051 (02-2010) a
  11
- Timing System
  11
- Brakes
  12
- Chassis
  12
- Suspension
  12
- Wheels
  12
- Electrical Components Location
  13
- Tyres
  13
- Overall Dimensions - Weight
  14
- Capacities
  16
- Maintenance
  17
- Troubleshooting
  21
- Settings and Adjustments
  27
Table of Contents

28
- Tank Removal
  30
- Valve Clearance Adjustment
  33
- Enrichener Lever Play Adjustment
  34
- Throttle Cable Adjustment
  34
- Engine Oil Level Check
  35
- Idle Adjustment
  35
- Engine Oil Replacement, Oil Filter Replacement
  36
- Mesh Filters Cleaning
  37
- Coolant Level Check
  39
- Coolant Replacement
  40
- Clutch Disassembly
  41
- Clutch Plate Replacement
  41
- Hydraulic Clutch Lever Adjustment and Fluid Level Check
  42
- Front Brake Lever Adjustment and Fluid Level Check
  43
- Rear Brake Pedal Adjustment
  44
- Rear Brake Pedal Free Play Adjustment
  44
- Air Filter Check
  45
- Rear Brake Fluid Level Check
  45
- Air Filter Cleaning
  46
- Chain Adjustment
  47
- Chain Lubrication
  48
- Lubricating an O-Ring Chain
  48
- Washing a Chain Without O-Rings
  48
- Suspension
  49
- Shock Absorber Spring Preload Adjustment
  51
- MARZOCCHI Front Fork Adjustment
  53
- Fork Oil Level
  54
- MARZOCCHI Front Fork Springs
  55
- Steering Bearing Clearance Adjustment
  56
- Supply Hose Check
  57
- Exhaust System Check
  58
- General Procedures
  59
Table of Contents

60
- Foreword
  61
- Saddle Removal
  62
- Side Panel Removal
  62
- Battery Removal
  63
- Exhaust System Removal
  64
- Air Box Removal
  68
- Throttle Body Removal
  70
- Removing the Rear Chassis Complete with Mudguard
  72
- Fuel Tank Removal
  75
- Fuel Tank Disassembly (Scoops and Fuel Pump)
  78
- Expansion Tank Removal
  80
- Removing Utilities (Solenoid Starter, Relays, Fuses, Flasher)
  81
- Electronic Control Unit Removal
  82
- Ignition Coil Removal
  82
- Voltage Regulator Removal
  82
- Electric Cooling Fan Removal
  83
- Front Mudguard Removal
  83
- Horn Removal
  83
- Digital Dashboard Removal
  86
- Headlamp Fairing Removal
  87
- Ignition Switch Removal
  88
- Thermal Expansion Valve Removal
  89
- Engine Removal
  90
- Secondary Drive Chain Removal
  90
- Radiator Removal
  95
- Engine Disassembly
  97
Table of Contents

98
- Layout of Engine Components
  99
- Camshaft Removal
  100
- Cylinder Head Cover Removal
  100
- Water Pump Body Removal
  104
- Water Pump Disassembly
  104
- Cylinder Head Removal
  105
- Valve Removal
  108
- Cylinder Removal
  110
- Flywheel Removal
  111
- Piston Removal
  111
- Clutch Cover Removal
  114
- Oil Filters Removal
  115
- Clutch Disassembly
  116
- Clutch Actuator Removal
  119
- Starter Motor Flange Removal
  120
- Starter Motor Removal
  120
- Gearbox Drive Shaft Removal
  121
- Gear Sensor Removal
  123
- Crankcase, Crankshaft and Countershaft Disassembly
  124
- Left Crankcase Seal Replacement
  127
- Countershaft Removal
  128
- Gearbox Disassembly
  128
- Crankshaft Removal
  129
- Crankshaft Components Removal
  130
- Crankcase Bearings Removal
  131
- Right Crankcase Crankshaft Seal Removal
  131
- Oil Pump Disassembly
  132
- Stator Removal
  132
Engine Overhaul

133
- Cleaning Parts
  134
- Clearances
  134
- Cylinder Head
  134
- Valve Seat Refacing
  135
- Valve Guide
  137
- Valve Guide Replacement
  137
- Valve
  138
- Valve Spring
  138
- Valve Installation
  139
- Rocker Arm Inspection
  140
- Camshaft
  141
- Timing Chain and Gears
  142
- Timing Chain Tensioners
  142
- Cylinder
  143
- Piston
  143
- Cylinder to Piston Clearance
  144
- Piston Pin
  145
- Piston Ring to Cylinder Clearance
  146
- Piston Rings
  146
- Piston Ring to Groove Clearance
  147
- Balancing Countershaft
  148
- Big End Radial Clearance
  148
- Crankshaft
  149
- Crankshaft Straightness
  149
- Small End Bushing Replacement
  149
- Clutch
  150
- Clutch Spring
  151
- Friction Plate to Clutch Housing Clearance
  151
- Selector Drum
  153
- Shifter Forks and Gears
  153
- Selector Drum to Shifter Fork Pins Clearance
  154
- Oil Pump Disassembly
  155
- Engine Reassembly
  157
Table of Contents

158
- General
  159
- Assembly and Lubrication Instructions (CRANK- ALTERNATOR- LUBRICATION- LEFT CRANKCASE HALF)
  160
- Tightening Torque Figures
  161
- Assembly and Lubrication Instructions (CLUTCH - KICK START- LUBRICATION- RIGHT CRANKCASE HALF)
  162
- Gearbox - Gear Shift Control
  162
- Tightening Torque Figures
  163
- Assembly and Lubrication Instructions (HEAD - CYLINDER - PISTON - TIMING SYSTEM - WATER PUMP - SPARK PLUG)
  164
- Tightening Torque Figures
  167
- Input Shaft
  170
- Output Shaft
  170
- Crankcase Assembly
  173
- Gear Sensor Installation
  179
- Gear Shift Control Assembly
  180
- Countershaft Weight/Gear Installation
  183
- Crankshaft Gears Installation
  183
- Clutch Assembly
  186
- Piston and Cylinder Installation
  189
- Piston Ring Installation
  189
- Cylinder Head Gasket Selection Table
  191
- Cylinder Head Installation
  192
- Water Pump Installation
  194
- Timing Chain Tensioner Installation
  195
- Camshaft Installation
  196
- Cylinder Head Cover and Spark Plug Installation
  198
- Flywheel and Flywheel Cover Installation
  199
- Oil Pump and Filter Cartridge Assembly
  202
- Sprocket Installation
  202
- Right Crankcase Assembly
  203
- Clutch Actuator Installation
  204
- Front Suspension
  205
- Rear Suspension
  314
Rear Suspension

315
- Lubrication Points (Grease)
  316
- Rear Shock Absorber
  316
- Rear Suspension
  316
- Rear Shock Absorber Removal
  318
- Disassembling, Servicing and Assembling the Rear Shock Absorber
  319
- Shock Absorber Inspection
  320
- Piston Assembly Inspections
  323
- Seal Replacement
  323
- Checking the Setting
  324
- Floating Piston Removal
  327
- Reservoir Replacement
  327
- Shock Absorber Assembly
  328
- Shock Absorber Damping Adjustment
  332
- Disassembling and Servicing the Swinging Arm
  333
- Servicing the Rear Suspension Drop Drag Link
  335
- Servicing the Swinging Arm Shaft
  335
- Chain Roller, Chain Guide, Chain Slider
  336
- Brakes
  338
Brakes

339
- Braking System
  340
- Brake Disc
  341
- Pads Cleaning
  342
- Bleeding the Front Braking System (TE)
  344
- Bleeding the Front Braking System (SMS)
  345
- Bleeding the Rear Braking System
  347
- Electrical System
  352
Table of Contents

354
- Colour Coding Key
  356
- Key to Wiring Diagram
  356
- Wiring Diagram
  356
- Charging System
  361
- Wiring Diagram
  361
- Charging System Inspections
  362
- Current Loss at the Battery
  362
- Regulated Voltage
  362
- Generator Inspection
  363
- Colour Coding Key
  364
- Generator No-Load Performance
  364
- Voltage Regulator/Rectifier Inspection
  364
- Wiring Diagram
  364
- Starting System
  365
- Wiring Diagram
  365
- Starting System Inspection
  366
- Starter Motor Maintenance
  367
- Starter Motor Test Curves
  367
- Solenoid Starter Inspection
  368
- Solenoid Starter Wiring Diagram
  368
- Electronic Ignition System
  369
- Checking Ignition Coil Windings Resistance
  371
- Electronic Control Unit (ECU)
  372
- Spark Plug
  373
- Gear Position Sensor Inspection (GPS: Gear Position Sensor)
  374
- Battery
  375
- Battery Charger
  375
- Headlight Adjustment
  377
- Headlamp Bulbs Replacement
  378
- Number Plate Bulb Replacement
  380
- Tail Light Replacement
  380
- Rear Turning Indicator Removal
  381
- Turning Indicator Bulb Replacement
  381
- Front Turning Indicator Removal
  382
- Number Plate Light Removal
  383
- Number Plate Holder Removal
  384
- Rear Mudguard Removal
  384
- Colour Coding Key
  385
- Left-Hand Switch
  385
- Colour Coding Key
  386
- Right-Hand Switch
  386
- Fuses
  387
- Semiconductor Parts
  387
- Connectors
  388
- Couplers
  388
- Charging System
  393
- Electronic Ignition System
  393
- Starting System
  393
- Troubleshooting
  393
- Wiring
  394
- Cable Routing and Electrical Parts Installation Instructions
  395
- Coil Position and Connector Connection
  395
- Position of Utilities
  395
- Electronic Control Unit Position
  396
- Securing the Engine / Chassis / Battery Ground Cables
  396
- Securing the Starter Motor/Solenoid Starter Cable
  396
- Voltage Regulator Position
  396
- Electric Fan Connection
  397
- Injector Connection
  397
- MAQS Connector Connection
  397
  - Engine Water Temperature Connector
    397
  - Lambda Sensor Position and Connector
    398
- Wiring Connection to Voltage Regulator
  397
- Ignition Switch and Left-Hand Switch Connection
  398
- Right-Hand Switch Connection
  398
- Ignition and Gear Sensor Cable Connection
  399
- Rear Stop Connection
  399
- Securing the Handlebar Wiring Harness
  399
- Cable Routing
  400
- Headlamp, Front Turning Indicators, STOP Light Connection
  400
- Routing of Steering Head Tube Wiring
  400
- Securing the Dashboard Bracket Connectors
  400
- Securing the Gear Sensor, Lambda Sensor, Stop Micro Switch Cables
  401
- Securing the Wiring Harness to the Mudguard
  401
- Securing the Wiring Harness to the Rear Chassis
  401
- Important
  402
- Engine Cooling
  404
- Hydraulically Controlled Clutch
  410
  - Hydraulic Clutch System
    412
  - Draining Clutch Fluid
    413
  - Clutch Master Cylinder Servicing
    414
  - Bleeding the Clutch System
    415
- Optional Components
  418
- Fuel Injection System
  422
- Special Tools
  430
- Tightening Torque Figures
  432
- Chassis and Wheels
  442
  - Chassis
    444
  - Lubrication Points (Lubricant)
    445
  - Front Wheel
    446
  - Rear Wheel
    449
  - Wheel Servicing
    451
  - Wheel Axle Warpage
    451
  - Axle Runout over 100 MM
    451
  - Wheel Spokes
    452
  - Wheel Rim Warpage
    452
  - Rear Chain Sprocket, Secondary Drive Sprocket and Chain
    453
  - Tightening Torque Figures
    453
  - Checking Chain and Sprockets for Wear
    454

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