Husqvarna F2103P4 Manuals

Manuals and User Guides for Husqvarna F2103P4. We have 1 Husqvarna F2103P4 manual available for free PDF download: Repair Manual

Husqvarna F2103P4 Repair Manual (343 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 79.21 MB

Table of Contents
4
Removing the Timing Chain
6
Means of Representation
9
Symbols Used
9
Formats Used
9
Adjusting the Rebound Damping of the Shock Absorber
9
Safety Advice
10
Repair Manual
10
Degrees of Risk and Symbols
10
Work Rules
10
Important Notes
11
Manufacturer and Implied Warranty
11
Operating and Auxiliary Substances
11
Spare Parts, Accessories
11
Figures
11
Serial Numbers
12
Chassis Number
12
Key Number (FE EU/AU)
12
Engine Number
12
Fork Part Number
13
Shock Absorber Article Number
13
Motorcycle
14
Raising the Motorcycle with a Lift Stand
14
Removing the Motorcycle from the Lift Stand
14
Starting
14
Starting the Motorcycle for a Check
15
Fork, Triple Clamp
16
Adjusting the Compression Damping 9 of the Fork
16
Adjusting the Rebound Damping of 9.1 the Fork
16
Bleeding the Fork Legs
17
Cleaning the Dust Boots of the Fork Legs
17
Removing the Fork Legs
18
Installing the Fork Legs
18
Removing the Fork Protector
19
Installing the Fork Protector
19
Performing a Fork Service
20
Disassembling the Fork Legs
20
Removing the Spring
22
Disassembling the Cartridge
23
Disassembling the Piston Rod
24
Disassembling the Hydrostop Unit
26
Disassembling the Seal Ring 9.8 Retainer
26
Checking the Fork Legs
27
Assembling the Seal Ring Retainer
28
Assembling the Hydrostop Unit
28
Assembling the Piston Rod
29
Assembling the Cartridge
31
Assembling the Fork Legs
32
Lubricating the Steering Head Bearing
37
Removing the Lower Triple Clamp
37
Installing the Lower Triple Clamp
38
Checking the Play of the Steering Head Bearing
40
Adjusting the Steering Head Bearing Play
40
Changing the Steering Head Bearing
41
7 Handlebar,Controls
43
Handlebar Position
43
Adjusting the Handlebar Position
43
Adjusting the Basic Position of the Clutch Lever
44
Checking the Routing of the Throttle Cable
44
Checking the Play in the Throttle Cable
45
Adjusting the Play in the Throttle Cable
45
Frame
47
Removing the Engine Guard
47
Installing the Engine Guard
47
Checking the Frame
47
Shock Absorber, Swingarm
48
Adjusting the High-Speed Compression Damping of the Shock Absorber
48
Adjusting the Low-Speed Compression Damping of the Shock Absorber
48
Measuring Rear Wheel Sag Unloaded
50
Checking the Static Sag of the Shock Absorber
50
Checking the Riding Sag of the Shock Absorber
51
Adjusting the Spring Preload of the Shock Absorber
51
Adjusting the Riding Sag
52
Removing the Shock Absorber
53
Installing the Shock Absorber
54
Checking the Shock Absorber 12.9 Linkage
54
Servicing the Shock Absorber
56
Removing the Spring
57
Disassembling the Damper
58
Disassembling the Piston Rod
59
Disassembling the Seal Ring 13.1 Retainer
60
Changing the Pilot Bushing
61
Checking the Damper
62
Removing the Heim Joint
63
Installing the Heim Joint
64
Assembling Seal Ring Retainer
64
Assembling the Piston Rod
65
Assembling the Damper
67
Bleeding and Filling the Damper
69
Filling the Damper with Nitrogen
72
Installing the Spring
73
Checking the Swingarm
74
Checking the Swingarm Bearing for Play
74
Removing the Swingarm
75
Installing the Swingarm
76
Changing the Swingarm Bearing
78
Exhaust
81
Removing the Manifold
81
Installing the Manifold
83
Removing the Main Silencer
84
Installing the Main Silencer
85
Changing the Glass Fiber Yarn Filling in the Main Silencer
85
Cleaning the Spark Arrestor (FE US)
87
11 Air Filter
89
Removing the Air Filter Box Cover
89
Installing the Air Filter Box Cover
89
Removing the Air Filter
89
Installing the Air Filter
90
Cleaning the Air Filter and Air Filter Box
90
Sealing the Air Filter Box
91
12 Fuel Tank, Seat, Trim
92
Opening the Filler Cap
92
Closing the Filler Cap
93
Removing the Right Side Cover
93
Installing the Right Side Cover
93
Removing the Seat
94
Mounting the Seat
94
Removing the Fuel Tank
95
Installing the Fuel Tank
96
Changing the Fuel Screen
98
Changing the Fuel Filter
99
Changing the Fuel Pump
102
Checking the Fuel Pressure
103
13 Mask, Fender
105
Removing Front Fender
105
Installing Front Fender
105
Removing the Headlight Mask with the Headlight
106
Installing the Headlight Mask with the Headlight
107
14 Wheels
109
Checking the Tire Air Pressure
109
Checking the Tire Condition
109
Checking the Wheel Bearing for Play
110
Checking the Brake Discs
111
Checking Spoke Tension
111
Checking the Rim Run-Out
112
Front Wheel
113
Removing the Front Wheel
113
Installing the Front Wheel
114
Changing the Front Brake Disc
114
Changing Front Wheel Bearing
115
Rear Wheel
116
Removing the Rear Wheel
116
Installing the Rear Wheel
117
Changing the Rear Brake Disc
118
Checking the Chain Tension
119
Adjusting the Chain Tension
119
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
120
Checking for Chain Dirt Accumulation
123
Cleaning the Chain
123
Changing the Drivetrain Kit
123
Changing the Rear Wheel Bearing
125
15 Wiring Harness, Battery
128
Changing the Fuses of Individual Power Consumers
128
Changing the Main Fuse
129
Checking the Starter Relay
130
Removing the Battery
130
Installing the Battery
131
Recharging the Battery
131
Checking the Charging Voltage
133
Checking the Open-Circuit Current
133
16 Brake System
134
Checking the Front Brake Linings
134
Changing the Front Brake Linings
134
Checking the Free Travel of the Hand Brake Lever
136
Adjusting the Basic Position of the
137
Hand Brake Lever (FE US)
137
Adjusting Free Travel of Hand Brake Lever (FE EU/ AU)
137
Checking the Front Brake Fluid Level
138
Adding Front Brake Fluid
138
Changing the Front Brake Fluid
139
Checking the Rear Brake Linings
141
Changing the Rear Brake Linings
141
Checking the Free Travel of Foot
144
Brake Lever
144
Adjusting the Basic Position of the Foot Brake Lever
145
Checking the Rear Brake Fluid Level
145
Adding Rear Brake Fluid
146
Changing the Rear Brake Fluid
147
Lighting System, Instruments
150
Adjusting the Combination Instrument
150
Adjusting the Kilometers or Miles
151
Adjusting the Clock
151
Setting the Wheel Circumference
152
Adjusting the Service Display
152
Checking the Headlight Setting
153
Adjusting the Headlight Range
153
18 Engine
154
Removing the Engine
154
Installing the Engine
158
Engine Disassembly
164
Preparations
164
Removing the Clutch Push Rod
164
Removing the Spacer
164
Draining the Engine Oil
164
Removing the Oil Filter
165
Removing the Spark Plug
165
Removing the Valve Cover
166
Removing the Alternator Cover
166
Removing the Torque Limiter
167
Positioning the Engine at Ignition Top Dead Center
167
Removing the Timing Chain Tensioner
167
Removing the Camshafts
168
Removing the Cylinder Head
168
Removing the Piston
169
Removing the Starter Drive
169
Removing the Suction Pump
171
Removing the Water Pump Wheel
172
Removing the Clutch Cover
172
Removing the Clutch Discs
172
Removing the Clutch Basket
173
Removing the Shift Shaft
174
Removing the Shift Drum Locating Unit
174
Removing the Locking Lever
175
Removing the Force Pump
175
Removing the Primary Gear
176
Removing the Spacer
176
Removing the Left Section of the Engine Case
177
Removing the Shift Rails
177
Removing the Shift Drum
178
Removing the Shift Forks
178
Removing the Transmission Shafts
178
Removing the Crankshaft
179
Working on Individual Parts
179
Work on the Right Section of the Engine Case
179
Work on the Left Section of the Engine Case
181
Work on the Clutch Cover
182
Checking the Oil Pressure Regulator Valve
184
Checking the Lubrication System
185
Removing the Crankshaft Bearing Inner Race
185
Installing the Crankshaft Bearing Inner Race
186
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
186
Checking the Crankshaft Run-Out at the Bearing Pin
188
Measuring the Crankshaft End Play
188
Removing the Drive Wheel of the Balancer Shaft
189
Installing the Drive Wheel of the Balancer Shaft
189
Cylinder - Nikasil ® Coating
189
Checking/Measuring the Cylinder
190
Checking/Measuring the Piston
190
Measuring the Piston/Cylinder Mounting Clearance
191
Checking the Piston Ring End Gap
192
Checking the Camshafts
192
Work on the Intake Camshaft
192
Checking the Pivot Points of the Camshafts
193
Removing the Valves
194
Checking the Valves
195
Checking the Valve Springs
195
Checking the Valve Spring Seat
196
Checking the Cam Levers
196
Checking the Cylinder Head
196
Installing the Valves
197
Checking the Freewheel
198
Removing the Freewheel
198
Installing the Freewheel
199
Checking the Electric Starter Drive
200
Checking the Timing Assembly
201
Preparing the Timing Chain Tensioner for Installation
202
Checking the Clutch
203
Checking the Shift Mechanism
204
Preassembling the Shift Shaft
205
Disassembling the Main Shaft
206
Disassembling the Countershaft
207
Checking the Transmission
207
Assembling the Main Shaft
209
Assembling the Countershaft
209
Engine Assembly
211
Installing the Crankshaft
211
Installing the Transmission Shafts
211
Installing the Shift Forks
212
Installing the Shift Drum
212
Installing the Shift Rails
212
Installing the Left Engine Case
213
Installing the Spacer
214
Installing the Timing Chain
214
Installing the Primary Gear
215
Installing the Force Pump
215
Installing the Suction Pump
216
Installing the Locking Lever
217
Installing the Shift Drum Locating Unit
217
Installing the Shift Shaft
217
Installing the Clutch Basket
217
Installing the Clutch Discs
218
Installing the Clutch Cover
220
Installing the Water Pump Cover
221
Installing the Starter Drive
222
Installing the Piston
223
Installing the Cylinder Head
225
18.5.22 Installing the Camshafts
226
Installing the Timing Chain Tensioner
227
Checking the Valve Clearance
228
18.5.25 Adjusting the Valve Clearance
228
Installing the Torque Limiter
229
Installing the Alternator Cover
229
Installing the Valve Cover
230
Installing the Spark Plug
231
Installing the Oil Filter
231
Installing the Oil Screen
231
Installing the Spacer
232
Installing the Clutch Push Rod
232
Removing the Engine from the Engine Assembly Stand
233
19 Clutch
234
Checking/Correcting the Fluid Level of the Hydraulic Clutch
234
Changing the Hydraulic Clutch Fluid
235
20 Water Pump, Cooling System
236
Cooling System
236
Checking the Antifreeze and Coolant Level
236
Checking the Coolant Level
237
Draining the Coolant
238
Refilling Coolant
238
Lubrication System
240
Oil Circuit
240
Checking the Engine Oil Level
240
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
241
Adding Engine Oil
243
Checking the Engine Oil Pressure
244
22 Ignition System
246
Ignition Coil - Checking the Secondary Winding
246
Checking the Spark Plug Connector
246
Winding
246
Removing the Stator and Crankshaft Position Sensor
247
Installing the Stator and Crankshaft 30.11 Position Sensor
248
23 Cylinder Head
249
Checking the Valve Clearance
249
Adjusting the Valve Clearance
252
24 Electric Starter
254
Checking the Starter Motor
254
25 Throttle Valve Body
255
Adjusting the Idle Speed
255
Executing the Initialization Run
255
26 Technical Data
257
Engine
257
Tolerance, Engine Wear Limits
258
Engine Tightening Torques
258
Capacities
260
Engine Oil
260
Coolant
260
Fuel
260
Chassis
261
Electrical System
262
Tires
262
Fork
262
Shock Absorber
263
Chassis Tightening Torques
263
27 Cleaning, Care
266
Cleaning the Motorcycle
266
Checks and Maintenance Steps for Winter Operation
267
Storage
268
Preparing for Use after Storage
269
29 Service Schedule
270
Service Work as Additional Order)
271
Wiring Diagram
272
Fe Eu)
272
Fe Eu)
274
Fe Eu)
276
Fe Eu)
278
Fe Eu)
280
Fe Eu)
282
Fe Eu)
284
Fe Eu)
286
Fe Au)
288
Fe Au)
290
Fe Au)
292
Fe Au)
294
Fe Au)
296
Fe Au)
298
Fe Au)
300
Fe Au)
302
Fe Us)
304
Fe Us)
306
Fe Us)
308
Fe Us)
310
Fe Us)
312
Fe Us)
314
Substances
316
32 Auxiliary Substances
318
33 Special Tools
320
Standards
336
35 List of Abbreviations
337
Index
338

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Husqvarna F2103P4 Repair Manual (343 pages)

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