Husqvarna F2303R0 Manuals

Manuals and User Guides for Husqvarna F2303R0. We have 1 Husqvarna F2303R0 manual available for free PDF download: Repair Manual

Husqvarna F2303R0 Repair Manual (333 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 88.45 MB

Table of Contents
4
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 Part 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
Guideline
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
Screw, Bottom Triple M8
21
Guideline Screw, Top Triple M8
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
42
Installing the Lower Triple Clamp
43
Checking Steering Head Bearing Play
45
Changing the Steering Head Bearing
46
Adjusting Steering Head Bearing Play
47
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
Adjusting 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
Guideline Remaining Screws, M6
63
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 the Seal Ring Retainer
75
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
Checking the Heim Joint for Play
91
Changing the Heim Joint
91
Exhaust System
93
Removing the Manifold
93
Installing the Manifold
94
Removing the Main Silencer
95
Installing the Main Silencer
96
Of the Main Silencer
96
Nm (8.9 Lbf Ft)
97
11 Air Filter
98
Removing the Air Filter Box Cover
98
Installing the Air Filter Box Cover
98
Removing the Air Filter
98
Installing the Air Filter
99
Cleaning the Air Filter and Air Filter Box
99
Sealing the Air Filter Box
100
Fuel Tank, Seat, Trim
101
Opening Fuel Tank Filler Cap
101
Closing the Fuel Tank Filler Cap
101
Removing the Right Side Cover
102
Installing the Right Side Cover
102
Removing the Seat
102
Mounting the Seat
103
Removing the Fuel Tank
104
Installing the Fuel Tank
105
Checking the Fuel Pressure
107
Changing the Fuel Pump
108
Changing the Fuel Filter
111
Changing the Fuel Screen
114
13 Mask, Fender
116
Removing Front Fender
116
Installing Front Fender
116
Removing the Start Number Plate
117
Installing the Start Number Plate
117
14 Wheels
118
Checking Tire Pressure
118
Checking the Tire Condition
118
Checking the Wheel Bearing for Play
119
Checking the Brake Discs
120
Checking Spoke Tension
120
Checking the Rim Run-Out
121
Nm (14.8 Lbf Ft)
121
Nm (12.5 Lbf Ft)
121
Front Wheel
122
Removing the Front Wheel
122
Installing the Front Wheel
123
Changing the Front Brake Disc
124
Changing the Front Wheel Bearing
124
Rear Wheel
126
Removing the Rear Wheel
126
Installing the Rear Wheel
127
Changing the Rear Brake Disc
128
Checking the Chain Tension
128
Adjusting the Chain Tension
129
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
129
Checking for Chain Dirt Accumulation
132
Cleaning the Chain
132
Changing the Drivetrain Kit
133
Changing the Rear Wheel Bearing
135
Wiring Harness, Battery 15
137
Changing the Main Fuse
137
Of the 12 V Battery
138
Connecting the Negative Cable of the 12 V Battery
138
Removing the 12 V Battery
139
Installing the 12 V Battery
140
Charging the 12 V Battery
141
Checking the Charging Voltage
142
Checking the Open-Circuit Current
143
Checking the Capacitor
143
Checking the Starter Relay
144
16 Brake System
146
Checking the Front Brake Linings
146
Changing the Front Brake Linings
146
Adjusting the Basic Position of the
148
Hand Brake Lever
148
Checking the Front Brake Fluid Level
149
Adding Front Brake Fluid
149
Changing the Front Brake Fluid
150
Checking the Brake Linings of the Rear Brake
152
Changing the Rear Brake Linings
152
Checking the Free Travel of Foot
154
Brake Lever
154
Adjusting the Basic Position of the Foot Brake Lever
155
Checking the Rear Brake Fluid Level
155
Adding Rear Brake Fluid
156
Changing the Rear Brake Fluid
157
17 Engine
160
Removing the Engine
160
Installing the Engine
167
Nm (7.4 Lbf Ft)
168
Engine Disassembly
175
Preparations
175
Draining the Engine Oil
175
Removing the Clutch Push Rod
176
Removing the Starter Motor
177
Removing the Spark Plug
177
Removing the Valve Cover
177
Removing the Alternator Cover
177
Positioning the Engine at Ignition Top Dead Center
178
Removing the Timing Chain Tensioner
178
Removing the Camshaft
179
Removing the Cylinder Head
179
Removing the Piston
180
Removing the Rotor
180
Removing the Timing Chain
181
Removing the Suction Pump
181
Removing the Gear Position Sensor
182
Removing the Water Pump Cover
182
Removing the Clutch Cover
183
Removing the Clutch Discs
183
Removing the Clutch Basket
184
Removing the Torque Limiter
185
Removing the Starter Idler Gear
185
Removing the Force Pump
185
Removing the Shift Shaft
186
Removing the Shift Drum Locating Unit
187
Removing the Locking Lever
187
Primary Gear Wheel, Removing
187
Removing the Freewheel Gear
187
Removing the Left Engine Case Section
188
Removing the Shift Rails
189
Removing the Shift Drum
189
Removing the Shift Forks
189
Removing the Transmission Shafts
189
Removing the Crankshaft
190
Working on Individual Parts
190
Working on the Right Section of the Engine Case
190
Working on the Left Section of the Engine Case
192
Oil Pressure Control Valve, Removing
193
Spring Length of the Oil Pressure Control Valve, Checking
194
Oil Pressure Control Valve, Installing
194
Crankshaft Seal Ring in the Clutch Cover, Changing
194
Removing the Water Pump
194
Installing the Water Pump
195
Removing the Timing Chain
196
Sprocket
196
Installing the Timing Chain
196
Removing the Crankshaft Bearing Inner Race
197
Installing the Crankshaft Bearing Inner Race
197
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
198
Checking Crankshaft Run-Out at Bearing Pin
200
Measuring the Crankshaft End Play
200
Cylinder - Nikasil ® - Coating
201
Checking/Measuring the Cylinder
201
Checking/Measuring the Piston
202
Checking the Piston Ring End Gap
203
Measuring the Piston/Cylinder Mounting Clearance
203
Checking the Oil Pumps
204
Disassembling the Autodecompressor
204
17 .4.23 Assembling the Autodecompressor
205
Checking Camshaft
206
Checking the Timing Assembly
206
Removing the Rocker Arm
207
Removing the Valves
207
Changing the Camshaft Bearing
208
Checking the Valves
209
Checking Valve Springs
210
Checking Valve Spring Seat
210
Checking the Cylinder Head
210
Checking the Rocker Arm Shafts
211
Installing the Valves
211
Installing the Rocker Arm
212
Disassembling the Antihopping Clutch
213
Preassembling the Antihopping Clutch
215
Checking the Clutch
218
Checking the Shift Mechanism
220
Preassembling the Shift Shaft
221
Disassembling the Main Shaft
222
Disassembling the Countershaft
223
Checking the Transmission
223
17.4.44 Assembling the Main Shaft
225
17.4.45 Assembling the Countershaft
226
Checking the Starter Drive
227
Checking the Freewheel
228
Removing the Freewheel
228
Freewheel, Installing
228
Engine Assembly
229
Installing the Crankshaft
229
Installing the Transmission Shafts
230
Installing the Shift Forks
230
Installing the Shift Drum
231
Installing the Shift Rails
231
Installing the Left Engine Case
231
Installing the Freewheel Gear
232
Primary Gear Wheel, Installing
232
Installing the Locking Lever
233
Installing the Shift Drum Locating Unit
233
Installing the Shift Shaft
233
Installing the Force Pump
233
Installing the Starter Idler Gear
234
Installing the Torque Limiter
235
Installing the Clutch Basket
235
Installing the Clutch Discs
236
Installing the Clutch Cover
237
Installing the Water Pump Cover
238
Installing the Gear Position Sensor
239
Installing the Suction Pump
239
Installing the Timing Chain
240
Installing the Rotor
240
Installing the Piston
241
Installing the Cylinder Head
243
Installing the Camshaft
244
Installing the Timing Chain Tensioner
244
Checking the Valve Clearance
245
17.5.28 Adjusting the Valve Clearance
245
Installing the Alternator Cover
246
Installing the Valve Cover
246
Installing the Spark Plug
247
Installing the Starter Motor
247
Installing the Oil Filter
247
Installing the Clutch Push Rod
248
Installing the Oil Screens
248
Removing the Engine from the Engine Assembly Stand
249
18 Clutch
250
Checking/Correcting the Fluid Level of the Hydraulic Clutch
250
Changing the Hydraulic Clutch Fluid
251
Checking the Clutch
252
19 Water Pump, Cooling System
260
Cooling System
260
Checking the Antifreeze and Coolant Level
260
Checking the Coolant Level
261
Draining the Coolant
262
Refilling Coolant
262
Lubrication System
264
Oil Circuit
264
Checking the Engine Oil Level
264
Changing the Engine Oil and Oil Filter Cleaning the Oil Screens
265
Adding Engine Oil
268
Checking the Oil Pressure
269
Ignition System
271
Secondary Winding
271
Connector
271
Changing the Spark Plug
271
Winding
272
Removing the Stator
273
Installing the Stator
273
22 Cylinder Head
274
Checking the Valve Clearance
274
Adjusting the Valve Clearance
276
Electric Starter System
279
Checking the Starter Motor
279
24 Throttle Valve Body
280
Adjusting the Idle Speed
280
Performing the Initialization Run
280
25 Technical Data
282
Engine
282
Tolerance, Engine Wear Limits
283
Engine Tightening Torques
283
Capacities
285
Engine Oil
285
Coolant
285
Fuel
285
Chassis
285
Electrical System
286
Tires
286
Fork
287
Shock Absorber
287
Chassis Tightening Torques
288
26 Cleaning/Protective Treatment
290
Cleaning the Motorcycle
290
27 Storage
292
Preparing for Use after Storage
293
28 Service Schedule
294
Additional Information
294
Required Work
294
Recommended Work
295
Wiring Diagram 29
297
Ignition Coil - Checking the 30 SUBSTANCES
302
Auxiliary Substances
304
Special Tools
306
Standards
326
List of Abbreviations
327
Index
328

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Husqvarna F2303R0 Repair Manual (333 pages)

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