Husqvarna NUDA 900 R 2012 - User Manual

Husqvarna NUDA 900 R 2012

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NUDA 900 2012/2013

NUDA 900 R 2012/2013

Workshop Manual Ed. 11-2011

Rev 02

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
- General Information12
- Clutch13
- Fuel System13
- Ignition13
- Lubrication13
- Primary Drive13
- Technical Data13
- Timing System13
- Transmission13
- Chassis14
- Front Brake14
- Front Suspension14
- Rear Suspension14
- Secondary Drive14
- Rear Brake15
- Rims15
- Tyres15
- Weight, Capacity15
- Electrical Components Location16
- The Electrical System Includes the Following Elements...16
- Dimensions17
Maintenance19
- Maintenance20
- Scheduled Maintenance Chart20
Troubleshooting23
- Engine Troubleshooting24
- Chassis Troubleshooting30
- Electrical System Troubleshooting31
Settings and Adjustments33
- Settings and Adjustments34
- Saddle Removal35
- Central Cover Removal36
- Side Panel Removal37
- Throttle Cable Adjustment37
- Front Brake Control38
- Position Adjustment38
- Throttle Control38
- Throttle Position Adjustment38
- Front Brake Lever Adjustment and Fluid Level Check39
- Clutch Control Lever Distance Adjustment40
- Position of the Clutch Control Adjustment40
- Clutch Free Play Adjustment41
- Rear Brake Pedal Free Play Adjustment41
- Oil Level Check42
- Rear Brake Fluid 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
- General Procedures62
- Stand Removal / Replacement63
- Stand Foot Replacement64
- Saddle Removal65
- To Remove the Saddle65
- Air-Box Cover Removal66
- Number Plate Holder Removal67
- Side Panels 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
- Coil / Stick-Coil Removal and Spark Plug Test91
- To Remove Spark Plug91
- Horn Removal92
- Radiator Removal92
- Electric Fan Removal94
- Gearbox Lever Removal94
- Battery Housing Removal95
- Engine Removal97
- Engine Reassembly100
  - Engine Settings and Adjustments104
  - Checking Cylinder “1” Valve Clearance105
  - Checking Cylinder “2” Valve Clearance105
- Valve Clearance Check105
- Valve Clearance Measurement105
- Half-Ball Replacement106
- Locking the Crankshaft106
- Camshaft Mount Disassembly107
- Camshaft Removal107
- Chain Tensioner Disassembly107
- Half-Ball Replacement107
- 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
- General Engine Procedures116
- Cover Removal117
- Gearbox Lever Removal/Installation117
- Left Clutch Side Cover Removal/Installation117
- Oil Dipstick Removal117
- Clutch Disengagement Shaft Oil Seal Removal118
- Gearbox Selector Shaft Oil Seal Removal/Installation118
- Clutch Disengagement Shaft Oil Seal Installation119
- Clutch Disengagement Shaft Upper Bearing Removal119
- Disengagement Shaft Installation119
- Installation of both Clutch Disengagement Shaft Bearings119
- Left Engine Crankcase Cover Assembly120
- Oil Dipstick Installation120
- Tightening Sequence of the Left Engine Crankcase Cover120
- Right Engine Crankcase Removal/Replacement121
- Stator Assembly121
- Stator Disassembly121
- Right Engine Crankcase Cover Installation122
- Tightening Sequence of the Right Engine Crankcase Cover122
- Flywheel and Starter Motor Idle Gear Removal123
- Freewheel Control Gear Removal123
- Removal/Installation of the Freewheel From/On the Flywheel123
- Installation of the Flywheel with Freewheel Control Gear124
- Starter Motor Idle Gear Removal/Installation124
- Chain Sprocket Removal/Installation125
- Crankshaft Position Sensor 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
- Mesh Oil Filter Replacement140
- Oil Sump Removal/Installation140
- 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
- Cylinder Head Removal/Disassembly148
- Cylinder Head Cover Removal/Installation149
- Removal of the Ignition Coil from the Spark Plug Recess149
- Chain Tensioner Removal/Installation150
- Crankshaft Locking Screw Removal151
  - Lock the Crankshaft151
  - 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
- Crankcase Disassembly164
- Crankcase Disassembly166
- Gearbox Removal166
- Gearbox Output Shaft Disassembly167
- Gearbox Input Shaft Disassembly169
- Gearbox Fork Removal170
- Ratchet Removal170
- Shift Drum Star Removal170
- Gear Selection Drum Disassembly171
- Gear Selection Drum Removal171
- Compensation Arm Removal172
- Connecting Rod Cap Removal172
- Crankshaft Removal172
- Crankshaft Removal173
- Main Bearing Cap Removal173
- Chain Tensioner Slider Removal174
- Main Split Bearing Removal174
- Piston Removal174
- Piston Ring Assembly175
- Piston Ring Removal175
- Installing the Pistons with the Connecting Rod176
- Piston Installation176
- Chain Tensioning Slider Installation177
- Crankshaft Installation177
- Main Split Bearing Installation177
- Connecting Rod Cap Installation178
- Main Bearing Cap Installation178
- Compensation Arm Installation179
- Gear Selector Drum Installation180
  - Installation of the 1St/3Rd and 2Nd/4Th Gear Engagement Fork180
  - Installation of the 5Th/6The Gear Engagement Fork180
- Ratchet Installation180
- St /3 Rd and 2 Nd /4 Th Gear Engagement Fork180
- Reassembly of the Gearbox Input and Output Shaft181
- Star-Shaped Stop Element Installation181
- 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
Engine Torque Figures188
Wear Limits of Engine Parts201
- Wear Limits of Engine Parts202
- Compensation Connecting Rod Compensation Arm203
- Connecting Rod203
- Crankshaft / Casing Assy203
- Engine Wear Value Table203
- Gearbox204
- Gear Shift Control205
- Clutch206
- Piston206
- Cylinders / Casing Assy207
- Head207
- Piston Pin207
- Timing Chain207
- Valves208
- Oil Pump (Engine Wear Value Table)209
- Spark Plug209
- Starting Device209
Front Suspension211
- Front Suspension212
- 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 Suspension231
- Rear Suspension232
- Rear Shock Absorber Removal233
- Rear Suspension233
- 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
- Checking Brake Pads for Wear / Replacing the Pads250
  - Rear Pads Assembly250
  - Rear Pads Disassembly250
  - 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
  - ABS Circuit Diagram261
- Braking System (ABS)261
- Brake Disc Checks264
- Removing the Braking System265
- Diagram of Location of Lines266
- Replacing a Brake Line266
- 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
- Checking Brake Pads for Wear / Replacing the Pads272
- Changing the Front Braking System Fluid275
  - Fluid Replacement, System Bleeding275
  - To Replace Brake Fluid275
- Changing the Rear Braking System Fluid276
- Bleed the Front Braking System277
- Bleed the Rear Braking System279
Electrical System281
- Electrical System282
- Electrical System284
- 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
- Crankshaft Position Sensor297
- Gear Position Sensor297
- Ignition and Injection System298
- Charging System299
- Battery Inspection300
- Charging System Inspections300
- Regulated Voltage300
- Voltage Regulator Inspection300
- Voltage Regulator/Rectifier Wiring Diagram300
- Electric Starting System301
- Solenoid Starter Inspection302
- Starter Motor302
- Starter Motor Inspection302
- Starter Relay Wiring Diagram302
- Starting System Inspection302
- Coil Windings / Stick-Coil Inspection303
- Electronic Control Unit (ECU)303
- Battery Charger304
- Spark Plug Inspection304
- Headlight Adjustment305
- Headlight, Tail Light305
- Front Headlamp Bulb Replacement306
- Headlight Removal307
- Tail Light Replacement308
- Turning Indicator Bulb 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
- Auxiliary Fuses 900 - 900R MY12315
- General Fuse 30A315
- Auxiliary Fuses 900 - 900R MY13316
- Relay Removal317
- Semiconductor Parts317
- Relay Test318
- Combined Dashboard319
- Warning Light Description320
- Clock Adjustment321
- Multifunction Display Description321
- Setting Units of Measurement322
  - Changing ECU Mapping323
  - CON Function323
- Setting Parameters323
- TRIP Function323
- Control Unit Removal324
- Combined Dashboard Replacement325
- Ignition Removal325
- Rear Stop Microswitch Replacement326
- Front Stop Microswitch Replacement327
- Speed Sensor Replacement327
- 12V Plug Replacement328
- Stand Rotative Switch Replacement328
- Water Temperature Sensor Replacement329
- Electronic Ignition System330
- Starting System330
- Troubleshooting330
- Electrical Connectors Positioning331
- Before Washing the Motorcycle334
- Important334
Engine Cooling335
- Engine Cooling336
- Checking Coolant Level337
- Coolant Replacement337
- To Replace Coolant337
- Cooling Circuit340
- Servicing the Engine Cooling System341
Tightening Torque Figures343
Standard Torque Values for the Different Thread Sizes349
Chassis and Wheels351
- Chassis and Wheels352
- Chassis353
- Lubrication Points (Lubricant)353
- Front Wheel Exploded View355
- Removing the Front Wheel357
- Refitting the Front Wheel358
- Rear Wheel Exploded View360
- Removing the Rear Wheel361
- Axle Runout over 100 MM362
- Wheel Axle Warpage362
- Wheel Rim Warpage362
- Checking Sprocket Wear363
- Rear Chain Sprocket, Secondary Drive Sprocket and Chain363

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Husqvarna NUDA 900 R 2012 Specifications

General

Brand	Husqvarna
Model	NUDA 900 R 2012
Category	Motorcycle
Language	English

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