Husqvarna F2101R1 Manuals

Manuals and User Guides for Husqvarna F2101R1. We have 1 Husqvarna F2101R1 manual available for free PDF download: Repair Manual

Husqvarna F2101R1 Repair Manual (330 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 86.39 MB

Table of Contents
4
Checking the Starter Motor
6
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 Article 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
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
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
Setting 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
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 Seal Ring Retainer
74
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
Changing the Heim Joint
90
Checking the Heim Joint for Play
92
Exhaust System
93
Removing the Manifold
93
Installing the Manifold
94
Removing the Main Silencer
95
Installing the Main Silencer
95
Changing the Glass Fiber Yarn Filling of the Main Silencer
96
Air Filter 11
97
Removing the Air Filter Box Cover
97
Installing the Air Filter Box Cover
97
Removing the Air Filter
97
Installing the Air Filter
98
Cleaning the Air Filter and Air Filter Box
98
Sealing the Air Filter Box
99
12 Fuel Tank, Seat, Trim
100
Opening Fuel Tank Filler Cap
100
Closing the Fuel Tank Filler Cap
100
Removing the Right Side Cover
101
Installing the Right Side Cover
101
Removing the Seat
101
Mounting the Seat
102
Removing the Fuel Tank
103
Installing the Fuel Tank
104
Checking the Fuel Pressure
106
Changing the Fuel Pump
107
Changing the Fuel Filter
110
Changing the Fuel Screen
113
Mask, Fender 13
115
Removing Front Fender
115
Installing Front Fender
115
Removing the Start Number Plate
116
Installing the Start Number Plate
116
Wheels 14
117
Checking Tire Pressure
117
Checking the Tire Condition
117
Checking the Wheel Bearing for Play
118
Checking the Brake Discs
118
Checking Spoke Tension
119
Checking the Rim Run-Out
119
Frontwheel
120
Removing the Front Wheel
120
Installing the Front Wheel
121
Changing the Front Brake Disc
122
Changing the Front Wheel Bearing
122
Rear Wheel
124
Removing the Rear Wheel
124
Installing the Rear Wheel
125
Changing the Rear Brake Disc
126
Checking the Chain Tension
127
Adjusting the Chain Tension
128
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
128
Checking for Chain Dirt Accumulation
131
Cleaning the Chain
131
Changing the Drivetrain Kit
132
Changing the Rear Wheel Bearing
134
15 Wiring Harness, Battery
136
Changing the Main Fuse
136
Of the 12 V Battery
137
Connecting the Negative Cable of the 12 V Battery
137
Removing the 12 V Battery
138
Installing the 12 V Battery
139
Charging the 12 V Battery
139
Checking the Charging Voltage
141
Checking the Open-Circuit Current
141
Checking the Capacitor
142
Checking the Starter Relay
143
16 Brake System
144
Checking the Front Brake Linings
144
Changing the Front Brake Linings
144
Checking the Free Travel of the Hand Brake Lever (Option: 17.3.26 Brembo)
147
Hand Brake Lever
148
Checking the Front Brake Fluid Level
149
Adding Front Brake Fluid
149
Changing the Front Brake Fluid
151
Checking the Brake Linings of the Rear Brake
154
Changing the Rear Brake Linings
155
Brake Lever
158
Foot Brake Lever
158
Checking the Rear Brake Fluid Level
160
Adding Rear Brake Fluid
160
Changing the Rear Brake Fluid
162
17 Engine
166
Removing the Engine
166
Installing the Engine
173
Engine Disassembly
181
Preparations
181
Removing the Clutch Push Rod
181
Draining the Engine Oil
181
Removing the Oil Filter
182
Gear Position Sensor, Removing
182
Removing the Spark Plug
183
Removing the Valve Cover
183
Starter Motor, Removing
184
Positioning the Engine at Ignition Top Dead Center
184
Removing the Timing Chain Tensioner
185
Removing the Camshafts
185
Cylinder Head, Removing
186
Removing the Piston
186
Removing the Rotor
187
Starter Drive, Removing
187
Removing the Suction Pump
188
17.3.17 Water Pump Impeller, Removing
189
Removing the Clutch Cover
189
Removing the Clutch Discs
190
Removing the Clutch Basket
190
Removing the Primary Gear Wheel
191
Timing Chain, Removing
191
Removing the Force Pump
192
Removing the Locking Lever
192
Shift Drum Locating Unit, Removing
193
Removing the Shift Shaft
193
17.3.27 Spacer, Removing
193
Removing the Left Engine Case
193
Shift Rails, Removing
194
Removing the Shift Drum
194
Removing the Shift Forks
195
Removing the Transmission Shafts
195
Removing the Crankshaft
195
Working on Individual Parts
196
Working on the Right Section of the Engine Case
196
Working on the Left Section of the Engine Case
198
Work on the Clutch Cover
199
Checking the Oil Pressure
201
Control Valve
201
Checking the Lubrication System
202
Removing the Crankshaft Bearing Inner Race
202
Installing the Crankshaft Bearing Inner Race
203
Connecting Rod, Conrod Bearing, and Crank Pin, Changing
203
Checking the Crankshaft Run-Out at the Bearing Pin
205
Measuring the Crankshaft End Play
206
Removing the Drive Gear Wheel of the Balancer Shaft
206
Installing the Drive Gear Wheel of the Balancer Shaft
207
Cylinder - Nikasil ® Coating
207
Checking/Measuring the Cylinder
207
Checking/Measuring the Piston
208
Measuring the Piston/Cylinder Mounting Clearance
209
Checking the Piston Ring End Gap
209
Camshafts, Checking
210
Checking the Pivot Points of the Camshafts
210
Valves, Removing
211
Valves, Checking
212
Valve Springs, Checking
212
Checking the Valve Spring Seat
213
Checking the Cam Levers
213
Checking the Cylinder Head
213
Installing the Valves
214
Checking the Freewheel
215
Freewheel, Removing
215
Freewheel, Installing
216
Checking the Electric Starter Drive
217
Checking the Timing Assembly
218
Preparing the Timing Chain Tensioner for Installation
219
Checking the Clutch
220
Checking the Shift Mechanism
221
Preassembling the Shift Shaft
222
Disassembling the Main Shaft
223
Disassembling the Countershaft
224
Checking the Transmission
224
Assembling the Main Shaft
226
Assembling the Countershaft
227
Engine Assembly
228
Installing the Crankshaft
228
Installing the Transmission Shafts
228
Shift Forks, Installing
229
Installing the Shift Drum
229
Shift Rails, Installing
229
Left Engine Case, Installing
230
Installing the Spacer
230
Shift Shaft, Installing
231
Shift Drum Locating Unit, Installing
231
Locking Lever, Installing
231
Installing the Force Pump
231
Installing the Suction Pump
232
Installing the Timing Chain
233
Installing the Primary Gear Wheel
234
Installing the Clutch Basket
234
Installing the Clutch Discs
235
Installing the Clutch Cover
236
Water Pump Cover, Installing
237
Starter Drive, Installing
238
Installing the Rotor
238
Installing the Piston
238
Installing the Cylinder Head
240
Installing the Camshafts
241
Installing the Timing Chain Tensioner
242
Checking the Valve Clearance
242
Adjusting the Valve Clearance
243
Installing the Starter Motor
244
Installing the Valve Cover
244
Spark Plug, Installing
245
Gear Position Sensor, Installing
245
Installing the Oil Filter
246
Installing the Oil Screen
246
Installing the Clutch Push Rod
247
Removing the Engine from the Engine Assembly Stand
247
18 Clutch
248
Checking/Correcting the Fluid Level of the Hydraulic Clutch
248
Changing the Hydraulic Clutch Fluid
249
Checking the Clutch
250
Water Pump, Cooling System 19
257
Cooling System
257
Checking the Antifreeze and Coolant Level
257
Checking the Coolant Level
258
Draining the Coolant
259
Refilling with Coolant
259
Lubrication System
261
Oil Circuit
261
Checking the Engine Oil Level
261
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
262
Adding Engine Oil
265
Checking the Oil Pressure
266
Ignition System
268
Ignition Coil - Checking the Secondary Winding
268
Connector
268
Alternator - Checking the Stator Winding
268
Crankshaft Speed Sensor
269
Speed Sensor
269
Changing the Spark Plug
270
22 Cylinder Head
272
Checking the Valve Clearance
272
Adjusting the Valve Clearance
275
23 Electric Starter System
276
Throttle Valve Body 24
277
Adjusting the Idle Speed
277
Performing the Initialization Run
277
Technical Data 25
279
Engine
279
Tolerance, Engine Wear Limits
280
Engine Tightening Torques
281
Capacities
283
Engine Oil
283
Coolant
283
Fuel
283
Chassis
283
Electrical System
284
Tires
284
Fork
284
Shock Absorber
285
Chassis Tightening Torques
285
26 Cleaning/Protective Treatment
288
Cleaning the Motorcycle
288
27 Storage
290
Putting into Operation after Storage
291
28 Service Schedule
292
Additional Information
292
Required Work
292
Recommended Work
293
Wiring Diagram 29
295
30 Substances
300
Auxiliary Substances
302
32 Special Tools
304
Standards 33
323
34 List of Abbreviations
324
Index
325

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