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F2475P4
User Manuals: Husqvarna F2475P4 Motorcycle Parts
Manuals and User Guides for Husqvarna F2475P4 Motorcycle Parts. We have
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Husqvarna F2475P4 Motorcycle Parts manual available for free PDF download: Repair Manual
Husqvarna F2475P4 Repair Manual (380 pages)
Brand:
Husqvarna
| Category:
Motorcycle
| Size: 86.71 MB
Table of Contents
Table of Contents
4
Means of Representation
10
Symbols Used
10
Formats Used
10
Safety Advice
11
Repair Manual
11
Degrees of Risk and Symbols
11
Work Rules
11
Important Notes
12
Manufacturer and Implied Warranty
12
Operating and Auxiliary Substances
12
Spare Parts, Accessories
12
Figures
12
Serial Numbers
13
Chassis Number
13
Type Label (FE EU/AU, FE 501 S US)
13
Key Number (FE EU/AU, FE 501 S US)
14
Engine Number
14
Fork Part Number
14
Shock Absorber Article Number
15
Motorcycle
16
Raising the Motorcycle with a Lift Stand
16
Removing the Motorcycle from the Lift Stand
16
Starting
16
Starting the Motorcycle to Check the Function
17
Fork, Triple Clamp
18
Adjusting the Compression Damping 9 of the Fork
18
Adjusting the Rebound Damping of 9.1 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
20
Removing the Fork Protector
22
Installing the Fork Protector
22
Performing a Fork Service
22
Disassembling the Fork Legs
23
Removing the Spring
25
Disassembling the Cartridge
26
Disassembling the Piston Rod
27
Disassembling the Hydrostop Unit
28
Disassembling the Seal Ring Retainer
29
Checking the Fork Legs
29
Assembling the Seal Ring Retainer
31
Assembling the Hydrostop Unit
31
Assembling the Piston Rod
32
Assembling the Cartridge
33
Assembling the Fork Legs
35
Lubricating the Steering Head Bearing
39
Removing the Lower Triple Clamp
40
Installing the Lower Triple Clamp
41
Checking the Play of the Steering Head Bearing
43
Changing the Steering Head Bearing
44
Adjusting the Steering Head Bearing Play
45
7 Handlebar,Controls
47
Handlebar Position
47
Adjusting the Handlebar Position
47
Adjusting the Basic Position of the Clutch Lever
48
Checking the Routing of the Throttle Cable
48
Checking the Play in the Throttle Cable
49
Adjusting the Play in the Throttle Cable
50
Frame
52
Removing the Engine Guard
52
Installing the Engine Guard
52
Checking the Frame
52
Shock Absorber, Swingarm
53
Adjusting the High-Speed Compression Damping of the Shock Absorber
53
Adjusting the Low-Speed Compression Damping of the Shock Absorber
53
Adjusting the Rebound Damping of the Shock Absorber
54
Measuring Rear Wheel Sag Unloaded
55
Checking the Static Sag of the Shock Absorber
55
Checking the Riding Sag of the Shock Absorber
56
Shock Absorber
56
Adjusting the Riding Sag
57
Removing the Shock Absorber
58
Installing the Shock Absorber
59
Checking the Shock Absorber Linkage
59
Servicing the Shock Absorber
61
Removing the Spring
62
Disassembling the Damper
63
Disassembling the Piston Rod
64
Disassembling the Seal Ring Retainer
65
Changing the Pilot Bushing
66
Checking the Damper
67
Removing the Heim Joint
68
Installing the Heim Joint
69
Assembling Seal Ring Retainer
69
Assembling the Piston Rod
70
Assembling the Damper
72
Bleeding and Filling the Damper
74
Filling Damper with Nitrogen
77
Installing the Spring
78
Checking the Swingarm
79
Checking the Swingarm Bearing for Play
79
Removing the Swingarm
80
Installing the Swingarm
81
Changing the Swingarm Bearing
83
10 Exhaust
86
Removing the Manifold
86
Installing the Manifold
88
Removing the Main Silencer
90
Installing the Main Silencer
90
Changing the Glass Fiber Yarn Filling in the Main Silencer
91
(Fe 450/501 Us, Fe 501 S Us)
92
11 Air Filter
95
Removing the Air Filter Box Cover
95
Installing the Air Filter Box Cover
95
Removing the Air Filter
95
Installing the Air Filter
96
Cleaning the Air Filter and Air Filter Box
96
Sealing the Air Filter Box
97
12 Fuel Tank, Seat, Trim
98
Opening the Filler Cap
98
Closing the Filler Cap
99
Removing the Right Side Cover
99
Installing the Right Side Cover
99
Removing the Seat
100
Mounting the Seat
100
Removing the Fuel Tank
101
Installing the Fuel Tank
103
Changing the Fuel Screen
105
Changing the Fuel Filter
106
Changing the Fuel Pump
108
Checking the Fuel Pressure
110
Removing the Activated Charcoal Filter (FE 501 SUS)
112
Installing the Activated Charcoal Filter (FE 501 SUS)
112
13 Mask, Fender
114
Removing Front Fender
114
Installing Front Fender
115
Removing the Headlight Mask with the Headlight
116
Installing the Headlight Mask with the Headlight
117
14 Wheels
120
Checking the Tire Air Pressure
120
Checking the Tire Condition
120
Checking the Wheel Bearing for Play
121
Checking the Brake Discs
122
Checking Spoke Tension
122
Checking the Rim Run-Out
123
Front Wheel
124
Removing the Front Wheel
124
Installing the Front Wheel
125
Changing the Front Brake Discs
125
Changing Front Wheel Bearing
126
Rear Wheel
127
Removing the Rear Wheel
127
Installing the Rear Wheel
129
Changing the Rear Brake Disc
130
Checking the Chain Tension
131
Adjusting the Chain Tension
132
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
133
Checking for Chain Dirt Accumulation
136
Cleaning the Chain
136
Changing the Drivetrain Kit
136
Changing the Rear Wheel Bearing
139
15 Wiring Harness, Battery
143
Changing the Fuses of Individual Power Consumers
143
Changing the Main Fuse
145
Checking the Starter Relay
146
Removing the Battery
146
Installing the Battery
147
Recharging the Battery
147
Checking the Charging Voltage
149
Checking the Open-Circuit Current
149
16 Brake System
150
Checking the Front Brake Linings
150
Changing the Front Brake Linings
150
Checking the Free Travel of the Hand Brake Lever
153
Adjusting Free Travel of Hand Brake Lever (FE EU/AU, FE 501 S US)
153
Adjusting the Basic Position of the Hand Brake Lever (FE 450/501 US)
154
Checking the Front Brake Fluid Level
154
Adding Front Brake Fluid
155
Changing the Front Brake Fluid
156
Checking the Rear Brake Linings
159
Changing the Rear Brake Linings
160
Checking the Free Travel of Foot
162
Brake Lever
162
Adjusting the Basic Position of the Foot Brake Lever
163
Checking the Rear Brake Fluid Level
163
Adding Rear Brake Fluid
164
Changing the Rear Brake Fluid
165
Lighting System, Instruments
168
Adjusting the Combination Instrument
168
Adjusting the Kilometers or Miles
169
Adjusting the Clock
169
Setting the Wheel Circumference
170
Adjusting the Service Display
170
Checking the Headlight Setting
171
Adjusting the Headlight Range
171
18 Engine
173
Removing the Engine
173
Installing the Engine
178
Engine Disassembly
183
Preparations
183
Draining the Engine Oil
183
Removing the Clutch Push Rod
184
Removing the Oil Filter
184
Removing the Starter Motor
185
Removing the Spark Plug
185
Removing the Valve Cover
185
Removing the Alternator Cover
186
Positioning the Engine at Ignition Top Dead Center
186
Removing the Timing Chain Tensioner
187
Removing the Camshaft
187
Removing the Cylinder Head
188
Removing the Piston
188
Removing the Rotor
188
Removing the Timing Chain Guide Rail
189
Removing the Timing Chain Tensioning Rail
189
Removing the Timing Chain Securing Guide
189
Removing the Timing Chain
190
Removing the Ignition Pulse Generator
190
Removing the Suction Pump
190
Removing the Water Pump Cover
191
Removing the Clutch Cover
191
Removing the Clutch Discs
192
Removing the Primary Gear Nut
193
Removing the Outer Clutch Hub
193
Removing the Torque Limiter
194
Removing the Starter Idler Gear
194
Removing the Shift Shaft
194
Removing the Shift Drum Locating Unit
194
Removing the Locking Lever
195
Removing the Oil Pump Gear Wheels
195
Removing the Force Pump
196
Removing the Primary Gear
196
Removing the Freewheel Gear
196
Removing the Left Engine Case Section
197
Removing the Shift Rails
198
Removing the Shift Drum
198
Removing the Shift Forks
198
Removing the Transmission Shafts
198
Removing the Crankshaft
199
Working on Individual Parts
199
Work on the Right Section of the Engine Case
199
Working on the Left Section of the Engine Case
201
Removing the Oil Pressure Regulator Valve
203
Checking Spring Length of Oil Pressure Regulator Valve
203
Installing the Oil Pressure Regulator Valve
204
Removing the Crankshaft Seal Ring in the Clutch Cover
204
Installing the Crankshaft Seal Ring in the Clutch Cover
204
Removing the Water Pump
204
Installing the Water Pump
205
Removing the Timing Chain Sprocket
206
Installing the Timing Chain Sprocket
206
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
207
Checking Crankshaft Run-Out at Bearing Pin
209
Cylinder - Nikasil ® Coating
209
Checking/Measuring the Cylinder
209
Checking/Measuring the Piston
210
Checking the Piston Ring End Gap
211
Measuring the Piston/Cylinder Mounting Clearance
211
Checking the Oil Pumps
212
Disassembling the Autodecompressor
212
Assembling the Autodecompressor
213
Checking Camshaft
214
Checking the Timing Assembly
214
Removing the Rocker Arm
215
Removing the Valves
215
Changing the Camshaft Bearing
216
Checking the Valves
217
Checking Valve Springs
217
Checking Valve Spring Seat
218
Checking the Cylinder Head
218
Checking the Rocker Arm Shafts
219
Installing the Valves
219
Installing the Rocker Arm
220
Checking the Clutch
221
Checking the Shift Mechanism
222
Preassembling the Shift Shaft
223
Disassembling the Main Shaft
224
18.4.38 Assembling the Main Shaft
224
Disassembling the Countershaft
226
Assembling the Countershaft
226
Checking the Transmission
227
Checking the Starter Drive
229
Removing the Freewheel
230
Checking the Freewheel
230
Installing the Freewheel
230
Engine Assembly
231
Installing the Crankshaft
231
Installing the Transmission Shafts
231
Installing the Shift Forks
232
Installing the Shift Drum
232
Installing the Shift Rails
233
Installing the Left Engine Case
233
Installing the Freewheel Gear
234
Installing the Primary Gear
234
Installing the Force Pump
234
Installing the Oil Pump Gear Wheels
235
Installing the Locking Lever
235
Installing the Shift Drum Locating Unit
236
Installing the Shift Shaft
236
Installing the Starter Idler Gear
236
Installing the Torque Limiter
236
Installing the Outer Clutch Hub
237
Installing the Primary Gear Nut
237
Installing the Clutch Discs
238
Installing the Clutch Cover
240
Installing the Water Pump Cover
240
Installing the Suction Pump
241
Installing the Ignition Pulse Generator
241
Installing the Timing Chain
242
Installing the Timing Chain Securing Guide
242
Installing the Timing Chain Tensioning Rail
242
Installing the Timing Chain Guide Rail
242
Installing the Rotor
243
Installing the Piston
243
Installing the Cylinder Head
245
Installing the Camshaft
246
Installing the Timing Chain Tensioner
246
Checking the Valve Clearance
247
Adjusting the Valve Clearance
247
Installing the Alternator Cover
248
Installing the Valve Cover
248
Installing the Spark Plug
249
Installing the Starter Motor
249
Installing the Oil Filter
249
Installing the Clutch Push Rod
250
Installing the Oil Screen
250
Removing the Engine from the Engine Assembly Stand
251
19 Clutch
252
Checking/Correcting the Fluid Level
252
Changing the Hydraulic Clutch Fluid
253
20 Water Pump, Cooling System
255
Cooling System
255
Checking the Antifreeze and Coolant Level
255
Checking the Coolant Level
256
Draining the Coolant
257
Refilling Coolant
258
Lubrication System
259
Oil Circuit
259
Checking the Engine Oil Level
259
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
260
Adding Engine Oil
262
Checking the Engine Oil Pressure
263
22 Ignition System
265
Ignition Coil - Checking the
265
Secondary Winding
265
Checking the Spark Plug Connector
265
Alternator - Checking the Stator 30.7 Winding
265
Removing the Stator
266
Installing the Stator
267
23 Cylinder Head
268
Checking the Valve Clearance
268
Adjusting Valve Clearance
270
24 Electric Starter
272
Checking the Starter Motor
272
25 Throttle Valve Body
273
Adjusting the Idle Speed
273
Executing the Initialization Run
273
26 Technical Data
275
Engine
275
Tolerance, Engine Wear Limits
276
Engine Tightening Torques
277
Capacities
279
Engine Oil
279
Coolant
279
Fuel
279
Chassis
279
Electrical System
280
Tires
281
Fork
281
Shock Absorber
281
Chassis Tightening Torques
282
27 Cleaning, Care
284
Cleaning the Motorcycle
284
Checks and Maintenance Steps for Winter Operation
285
Storage
286
Preparing for Use after Storage
287
29 Service Schedule
288
Service Work as Additional Order)
289
Fe Eu)
290
30 Wiring Diagram
291
Fe Eu)
292
Fe Eu)
294
Fe Eu)
296
Fe Eu)
298
Fe Eu)
300
Fe Eu)
302
Fe Eu)
304
Fe Au)
306
Fe Au)
308
Fe Au)
310
Fe Au)
312
Fe Au)
314
Fe Au)
316
Fe Au)
318
Fe Au)
320
Fe 450/501 Us)
322
Fe 450/501 Us)
324
Fe 450/501 Us)
326
Fe 450/501 Us)
328
Fe 450/501 Us)
330
Fe 450/501 Us)
332
Fe 501 S Us)
334
Fe 501 S Us)
336
Fe 501 S Us)
338
Fe 501 S Us)
340
Fe 501 S Us)
342
Fe 501 S Us)
344
Fe 501 S Us)
346
Fe 501 S Us)
348
Substances
350
32 Auxiliary Substances
352
33 Special Tools
354
Standards
372
35 List of Abbreviations
373
Index
374
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