Husqvarna F2303S0 Manuals

Manuals and User Guides for Husqvarna F2303S0. We have 1 Husqvarna F2303S0 manual available for free PDF download: Repair Manual

Husqvarna F2303S0 Repair Manual (337 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 86.06 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
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
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
93
Removing the Main Silencer
94
Installing the Main Silencer
95
Changing the Glass Fiber Yarn Filling of the Main Silencer
95
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
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
166
Engine Disassembly
172
Preparations
172
Draining the Engine Oil
173
Removing the Clutch Push Rod
173
Removing the Oil Filter
174
Removing the Starter Motor
174
Removing the Spark Plug
174
Removing the Valve Cover
175
Removing the Alternator Cover
175
Removing the Camshaft
177
Removing the Cylinder Head
177
Removing the Piston
178
Removing the Rotor
178
Removing the Timing Chain
179
Removing Suction Pump
179
Removing the Gear Position Sensor
180
Removing the Water Pump Cover
180
Removing the Clutch Cover
181
Removing the Clutch Discs
181
Removing the Clutch Basket
182
Removing the Torque Limiter
183
Removing the Starter Idler Gear
183
Removing the Force Pump
183
Removing the Shift Shaft
184
Removing the Shift Drum Locating Unit
185
Removing the Locking Lever
185
Primary Gear Wheel, Removing
185
Removing the Freewheel Gear
185
Removing the Left Engine Case Section
186
Removing the Shift Rails
187
Removing the Shift Drum
187
Removing the Shift Forks
187
Removing the Transmission Shafts
187
Removing the Crankshaft
188
Working on Individual Parts
188
Working on the Right Section of the Engine Case
188
Working on the Left Section of the Engine Case
190
Oil Pressure Control Valve, Removing
191
Spring Length of the Oil Pressure Control Valve, Checking
192
Oil Pressure Control Valve, Installing
192
Crankshaft Seal Ring in the Clutch Cover, Changing
192
Removing the Water Pump
192
Installing the Water Pump
193
Removing the Timing Chain
194
Sprocket
194
Installing the Timing Chain
194
Removing the Crankshaft Bearing Inner Race
195
Installing the Crankshaft Bearing Inner Race
195
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
196
Checking Crankshaft Run-Out at Bearing Pin
198
Measuring the Crankshaft End Play
198
Cylinder - Nikasil ® - Coating
199
Checking/Measuring the Cylinder
199
Checking/Measuring the Piston
200
Checking the Piston Ring End Gap
201
Measuring the Piston/Cylinder Mounting Clearance
201
Checking the Oil Pumps
202
Disassembling the Autodecompressor
202
17 .4.23 Assembling the Autodecompressor
203
Checking Camshaft
204
Checking the Timing Assembly
204
Removing the Rocker Arm
205
Removing the Valves
205
Changing the Camshaft Bearing
206
Checking the Valves
207
Checking Valve Springs
208
Checking Valve Spring Seat
208
Checking the Cylinder Head
208
Checking the Rocker Arm Shafts
209
Installing the Valves
209
Installing the Rocker Arm
210
Disassembling the Antihopping Clutch
211
Preassembling the Antihopping Clutch
213
Checking the Clutch
216
Checking the Shift Mechanism
218
Preassembling the Shift Shaft
219
Disassembling the Main Shaft
220
Disassembling the Countershaft
221
Checking the Transmission
221
17.4.44 Assembling the Main Shaft
223
17.4.45 Assembling the Countershaft
224
Checking the Starter Drive
225
Checking the Freewheel
226
Removing the Freewheel
226
Freewheel, Installing
226
Engine Assembly
227
Installing the Crankshaft
227
Installing the Transmission Shafts
228
Installing the Shift Forks
228
Installing the Shift Drum
229
Installing the Shift Rails
229
Installing the Left Engine Case
229
Installing the Freewheel Gear
230
Primary Gear Wheel, Installing
230
Installing the Locking Lever
231
Installing the Shift Drum Locating Unit
231
Installing the Shift Shaft
231
Installing the Force Pump
231
Installing the Starter Idler Gear
232
Installing the Torque Limiter
233
Installing the Clutch Basket
233
Installing the Clutch Discs
234
Installing the Clutch Cover
235
Installing the Water Pump Cover
236
Installing the Gear Position Sensor
237
Installing the Suction Pump
237
Installing the Timing Chain
238
Installing the Rotor
238
Installing the Piston
239
Installing the Cylinder Head
241
Installing the Camshaft
242
Installing the Timing Chain Tensioner
242
Checking the Valve Clearance
243
17.5.28 Adjusting the Valve Clearance
243
Installing the Alternator Cover
244
Installing the Valve Cover
244
Installing the Spark Plug
245
17.5.32 Installing the Starter Motor
245
17.5.33 Installing the Oil Filter
245
Installing the Clutch Push Rod
246
Installing the Oil Screens
246
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
19 Water Pump, Cooling System
258
Cooling System
258
Checking the Antifreeze and Coolant Level
258
Checking the Coolant Level
259
Draining the Coolant
260
Refilling Coolant
260
Changing the Coolant Pipe
261
Lubrication System
266
Oil Circuit
266
Checking the Engine Oil Level
266
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screens
267
Adding Engine Oil
270
Checking the Oil Pressure
271
Ignition System
273
Ignition Coil - Checking the
273
Secondary Winding
273
Connector
273
Changing the Spark Plug
273
Alternator - Checking Stator
274
Winding
274
Removing the Stator
275
Installing the Stator
275
22 Cylinder Head
276
Checking the Valve Clearance
276
Adjusting the Valve Clearance
278
Electric Starter System
281
Checking the Starter Motor
281
24 Throttle Valve Body
282
Adjusting the Idle Speed
282
Performing the Initialization Run
282
25 Technical Data
284
Engine
284
Tolerance, Engine Wear Limits
285
Engine Tightening Torques
285
Capacities
287
Engine Oil
287
Coolant
287
Fuel
287
Chassis
287
Electrical System
288
Tires
288
Fork
289
Shock Absorber
289
Chassis Tightening Torques
290
26 Cleaning/Protective Treatment
292
Cleaning the Motorcycle
292
27 Storage
294
Preparing for Use after Storage
295
28 Service Schedule
296
Additional Information
296
Required Work
296
Recommended Work
297
Wiring Diagram 29
301
Substances
306
Auxiliary Substances
308
Special Tools
310
List of Abbreviations
331
Index
332

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