Husqvarna F2303Q0 Manuals

Manuals and User Guides for Husqvarna F2303Q0. We have 1 Husqvarna F2303Q0 manual available for free PDF download: Repair Manual

Husqvarna F2303Q0 Repair Manual (322 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 85.83 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
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
41
Installing the Lower Triple Clamp
42
Checking Steering Head Bearing Play
44
Changing the Steering Head Bearing
45
Adjusting Steering Head Bearing Play
46
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
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
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
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
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
214
Checking the Clutch
215
Checking the Shift Mechanism
216
Preassembling the Shift Shaft
217
Disassembling the Main Shaft
218
Disassembling the Countershaft
219
Checking the Transmission
219
17.4.44 Assembling the Main Shaft
221
17.4.45 Assembling the Countershaft
222
Checking the Starter Drive
223
Checking the Freewheel
224
Removing the Freewheel
224
Freewheel, Installing
224
Engine Assembly
225
Installing the Crankshaft
225
Installing the Transmission Shafts
226
Installing the Shift Forks
226
Installing the Shift Drum
227
Installing the Shift Rails
227
Installing the Left Engine Case
227
Installing the Freewheel Gear
228
Primary Gear Wheel, Installing
228
Installing the Locking Lever
229
Installing the Shift Drum Locating Unit
229
Installing the Shift Shaft
229
Installing the Force Pump
229
Installing the Starter Idler Gear
230
Installing the Torque Limiter
231
Installing the Clutch Basket
231
Installing the Clutch Discs
232
Installing the Clutch Cover
233
Installing the Water Pump Cover
234
Installing the Gear Position Sensor
234
Installing the Suction Pump
234
Installing the Timing Chain
235
Installing the Rotor
236
Installing the Piston
236
Installing the Cylinder Head
238
Installing the Camshaft
239
Installing the Timing Chain Tensioner
239
Checking the Valve Clearance
240
17.5.28 Adjusting the Valve Clearance
241
Installing the Alternator Cover
241
Installing the Valve Cover
242
Installing the Spark Plug
242
Installing the Starter Motor
242
Installing the Oil Filter
242
Installing the Clutch Push Rod
243
Installing the Oil Screens
243
Removing the Engine from the Engine Assembly Stand
244
Clutch
245
Checking/Correcting the Fluid Level of the Hydraulic Clutch
245
Changing the Hydraulic Clutch Fluid
246
Anti Hopping Clutch
247
Adjusting the Antihopping Clutch
248
19 Water Pump, Cooling System
250
Cooling System
250
Checking the Antifreeze and Coolant Level
250
Checking the Coolant Level
251
Draining the Coolant
252
Refilling Coolant
252
Lubrication System
254
Oil Circuit
254
Checking the Engine Oil Level
254
Changing the Engine Oil and Oil Filter Cleaning the Oil Screens
255
Adding Engine Oil
258
Checking the Oil Pressure
259
Ignition System
261
Secondary Winding
261
Connector
261
Changing the Spark Plug
261
Winding
262
Removing the Stator
263
Installing the Stator
263
22 Cylinder Head
264
Checking the Valve Clearance
264
Adjusting the Valve Clearance
266
Electric Starter System
269
Checking the Starter Motor
269
24 Throttle Valve Body
270
Adjusting the Idle Speed
270
Performing the Initialization Run
270
25 Technical Data
272
Engine
272
Tolerance, Engine Wear Limits
273
Engine Tightening Torques
273
Capacities
275
Engine Oil
275
Coolant
275
Fuel
275
Chassis
275
Electrical System
276
Tires
276
Fork
277
Shock Absorber
277
Chassis Tightening Torques
278
26 Cleaning/Protective Treatment
280
Cleaning the Motorcycle
280
27 Storage
282
Preparing for Use after Storage
283
28 Service Schedule
284
Additional Information
284
Required Work
284
Recommended Work
285
Wiring Diagram 29
287
Ignition Coil - Checking the 30 SUBSTANCES
292
Auxiliary Substances
294
Special Tools
296
Standards
315
List of Abbreviations
316
Index
317

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