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Husqvarna NUDA 900 R 2013 User Manual

Husqvarna NUDA 900 R 2013
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NUDA 900 2012/2013
NUDA 900 R 2012/2013
Workshop Manual Ed. 11-2011
Rev 02

Table of Contents

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Husqvarna NUDA 900 R 2013 Specifications

General IconGeneral
BrandHusqvarna
ModelNUDA 900 R 2013
CategoryMotorcycle
LanguageEnglish

Summary

FOREWORD, TABLE OF CONTENTS

MODELS COVERED

Identifies the motorcycle models covered by the manual.

IMPORTANT NOTICES

GENERAL SAFETY WARNINGS

Provides essential safety recommendations for operating and maintaining the vehicle.

GENERAL INFORMATION

General Specifications

Covers engine, timing, lubrication, ignition, fuel, clutch, transmission, and drive systems.

Chassis and Suspension

Details chassis type, front and rear suspension specifications.

Brakes and Wheels

Covers front/rear brake systems, rims, tyres, and pressures.

Capacities and Lubrication

Lists weight, capacities, and recommended lubrication points.

Electrical Components

Identifies the location of various electrical system components.

MAINTENANCE

SCHEDULED MAINTENANCE CHART

Outlines scheduled maintenance intervals and tasks for engine and chassis components.

TROUBLESHOOTING

Engine Issues

Provides guidance on diagnosing and resolving engine running, starting, and performance issues.

SETTINGS AND ADJUSTMENTS

Bodywork and Controls Removal/Adjustment

Covers saddle, cover, side panel removal, and throttle cable adjustment.

Brake and Clutch Controls Adjustment

Details adjustments for front/rear brake levers and clutch controls.

Fluid Level Checks and Replacements

Covers brake fluid and oil level checks, and oil/filter replacement.

Coolant and Air Filter Maintenance

Guides on coolant checks/replacement and air filter inspection.

Chain and Suspension Adjustments

Explains chain adjustment, lubrication, and suspension settings.

Fork and Shock Absorber Servicing

Details spring preload and hydraulic damping adjustments for forks and shock absorbers.

Fuel and Exhaust System Checks

Covers inspection and replacement of fuel hoses and the exhaust system.

GENERAL PROCEDURES

Stand and Saddle Procedures

Covers stand removal/replacement and saddle removal.

Bodywork Component Removal

Guides on removing air-box cover, side panels, and number plate holder.

Lighting Component Removal

Details removal of tail light, rear indicators, and front fairing.

Dashboard and Mudguard Removal

Explains removal of the combined dashboard and front mudguard.

Battery and Fuel System Components

Guides on battery, reservoir, and fuel pump removal.

Filter Box and Throttle Body Removal

Details removal of the filter box and throttle body assemblies.

Exhaust and Lambda Sensor Removal

Guides on removing the exhaust system and lambda sensor.

Ignition and Cooling System Components

Covers ignition coil/spark plug removal, horn, and radiator removal.

Electric Fan and Gearbox Lever Removal

Details removal of electric fan and gearbox lever.

Battery Housing and Engine Removal

Guides on removing battery housing and the entire engine.

Engine Reassembly

Outlines the steps for reassembling the engine onto the motorcycle frame.

ENGINE SETTINGS AND ADJUSTMENTS

Valve Clearance and Timing Checks

Details checking valve clearance and engine timing.

Crankshaft and Camshaft Procedures

Covers crankshaft locking and camshaft mount disassembly/assembly.

Camshaft Removal and Installation

Guides on removing and installing camshafts and related components.

Engine Phasing and Chain Tensioner

Explains engine phasing and chain tensioner procedures.

GENERAL ENGINE PROCEDURES

Clutch Side Cover and Gearbox Procedures

Covers left clutch cover, gearbox lever, and oil dipstick removal.

Crankcase and Stator Procedures

Details left and right crankcase cover assembly and stator procedures.

Flywheel, Starter Motor, and Crankshaft Position Sensor

Covers removal/installation of flywheel, starter motor, and crankshaft sensor.

Gearbox and Clutch Procedures

Details complete clutch removal/installation and pressure plate disassembly.

Oil Pump Procedures

Guides on oil suction and force pump removal/installation.

Coolant Pump and Oil Sump Procedures

Details coolant pump and oil sump removal/installation.

Timing Chain and Heat Exchanger Procedures

Covers timing chain replacement and heat exchanger removal/installation.

CYLINDER HEAD REMOVAL/DISASSEMBLY

Ignition Coil and Cylinder Head Cover

Details removing ignition coil and cylinder head cover.

Chain Tensioner and Crankshaft Locking

Guides on chain tensioner removal/installation and crankshaft locking.

Camshaft Procedures

Covers camshaft mount disassembly/assembly and related checks.

Camshaft Removal and Installation

Details the procedure for removing and installing camshafts.

Timing Chain Slider Replacement

Guides on replacing timing chain sliders.

Rocker Arm Procedures

Details rocker arm removal, installation, and replacement.

Cylinder Head Gasket Replacement

Provides instructions for cylinder head removal/installation and gasket replacement.

Cylinder Head Disassembly and Valve Removal

Guides on disassembling the cylinder head and removing valves.

CRANKCASE DISASSEMBLY

Crankcase Disassembly Steps

Lists components to remove before disassembling the crankcase.

Gearbox and Shaft Procedures

Covers gearbox removal and output shaft disassembly.

Gearbox Input Shaft Disassembly

Details the disassembly of the gearbox input shaft.

Shift Drum, Ratchet, and Gearbox Fork Procedures

Guides on removing shift drum star, ratchet, and gearbox forks.

Gear Selection Drum Disassembly

Explains the disassembly of the gear selection drum.

Crankshaft Removal Procedures

Covers compensation arm, connecting rod cap, and crankshaft removal.

Piston and Ring Procedures

Guides on removing pistons, rings, and installing rings.

Crankshaft Installation and Bearing Procedures

Details installing crankshaft, split bearings, and chain tensioner slider.

Main Bearing and Connecting Rod Cap Installation

Explains installing main bearing caps and connecting rod caps.

Compensation Arm Installation

Guides on installing the compensation arm.

Gearbox Installation Procedures

Covers gear selector drum, engagement forks, and ratchet installation.

Crankcase Halves Fixing

Details installing the lower engine crankcase half and fixing crankcase halves.

Gearbox Output Shaft Oil Seal Installation

Explains how to install the gearbox output shaft oil seal.

ENGINE TORQUE FIGURES

Engine Component Torque Specifications

Lists tightening torques for engine mounts, radiator, and bodywork fasteners.

Chassis Component Torque Specifications

Provides torques for chassis, steering, and suspension mounting points.

Brake and Exhaust System Torques

Lists tightening torques for brake discs, pipes, exhaust, and throttle controls.

Engine Assembly Torque Sequences

Details tightening sequences and torques for engine-to-chassis and steering head components.

ABS System Torque Specifications

Lists tightening torques for ABS unit mounting and brake lines.

Standard Screw Torque Values

Provides standard torque values for various screw thread sizes.

WEAR LIMITS OF ENGINE PARTS

Engine Wear Value Table

Provides a comprehensive table of new values and wear limits for engine components.

Crankshaft and Connecting Rod Wear Limits

Lists wear values for crankshaft, casing, and connecting rod components.

Gearbox and Gear Shift Control Wear Limits

Details wear limits for gearbox components and gear shift control.

Clutch and Piston Wear Limits

Provides wear limits for clutch plates, piston diameter, and pin.

Cylinder and Head Wear Limits

Lists wear limits for cylinder bore, camshafts, and valve guides.

Valve Wear Limits

Details wear limits for intake/exhaust valve clearance and stem dimensions.

Oil Pump, Starting Device, and Spark Plug Wear

Covers wear limits for oil pump, starting device, and spark plug electrode gap.

FRONT SUSPENSION

Front End Components and Disassembly

Illustrates front end parts and guides on disassembly.

Front End Assembly and Settings

Details front end assembly and general suspension settings.

Fork Servicing and Bushing Replacement

Explains front fork servicing and replacement of bushings and seals.

Damper Servicing and Reassembly

Guides on servicing and reassembling the front fork damper.

REAR SUSPENSION

Rear Suspension Overview and Shock Removal

Describes the rear suspension system and guides on shock absorber removal.

Shock Absorber Spring Replacement

Details the procedure for replacing the rear shock absorber spring.

Mudguard, Sprocket Casing, and Swinging Arm Removal

Guides on removing mudguard, sprocket casing, and swinging arm.

Chain Slider Removal

Explains how to remove the chain upper and lower slides.

BRAKES

NON-ABS Version Specifics

Notes that this section applies only to the non-ABS MY12 models.

ABS Braking System Overview

Describes the ABS system, its components, and circuit diagram.

Brake Disc Checks and Replacements

Details checking brake disc thickness, distortion, and replacement procedures.

Braking System Removal

Guides on separating components and draining fluid before removal.

Brake Fluid Replacement and Bleeding

Provides comprehensive instructions for replacing brake fluid and bleeding the system.

Brake Pad Wear Check and Replacement

Guides on checking brake pad wear and replacing front and rear pads.

ELECTRICAL SYSTEM

Wiring Diagrams and Keys

Presents wiring diagrams for MY12 and MY13, with keys for components and colors.

Electrical Component Locations

Identifies the physical location of various electrical components on the motorcycle.

Charging System Inspection and Operation

Details charging system components and inspection procedures for battery and regulator.

Starting System Inspection

Provides procedures for inspecting the starter motor, solenoid, and relay.

Ignition and ECU Systems

Covers ignition coils, spark plugs, and the electronic control unit (ECU).

Lighting System Components

Describes headlight adjustment and bulb replacement procedures.

Switchgear and Fuse Management

Details left/right handlebar switches, fuses, and their functions.

Relay Testing and Semiconductor Parts

Guides on testing relays and handling semiconductor parts.

Dashboard and Warning Lights

Describes the combined dashboard layout and warning light indicators.

Troubleshooting Electrical Issues

Provides diagnostic guidance for charging, starting, and ignition system problems.

ENGINE COOLING

Coolant Level Check and Replacement

Guides on checking coolant level and replacing engine coolant.

Cooling Circuit Components

Illustrates the components of the engine cooling circuit, including radiator and pump.

Engine Cooling System Servicing

Provides maintenance advice for radiators, hoses, and clamps.

TIGHTENING TORQUE FIGURES

Engine Component Torque Specifications

Lists tightening torques for engine mounts, radiator, and bodywork fasteners.

Chassis Component Torque Specifications

Provides torques for chassis, steering, and suspension mounting points.

Brake and Exhaust System Torques

Lists tightening torques for brake discs, pipes, exhaust, and throttle controls.

Engine Assembly Torque Sequences

Details tightening sequences and torques for engine-to-chassis and steering head components.

ABS System Torque Specifications

Lists tightening torques for ABS unit mounting and brake lines.

Standard Screw Torque Values

Provides standard torque values for various screw thread sizes.

CHASSIS AND WHEELS

Chassis Description and Lubrication Points

Describes the chassis structure and identifies lubrication points.

Front Wheel Assembly and Removal

Illustrates front wheel components and guides on its removal.

Front Wheel Refitting Procedures

Details the correct procedure for refitting the front wheel.

Rear Wheel Assembly and Removal

Illustrates rear wheel components and guides on its removal.

Wheel Axle and Rim Trueness Checks

Explains how to check wheel axle runout and rim warpage.

Sprocket and Chain Wear Checks

Guides on checking sprocket wear and chain condition.

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