Husqvarna F2275P4 Motorcycle Cylinder Manuals

Manuals and User Guides for Husqvarna F2275P4 Motorcycle Cylinder. We have 1 Husqvarna F2275P4 Motorcycle Cylinder manual available for free PDF download: Repair Manual

Husqvarna F2275P4 Repair Manual (381 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 87.82 MB

Table of Contents
4
Means of Representation
9
Symbols Used
9
Formats Used
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
Type Label (FE EU/AU, 7 FE 350 S US)
12
Key Number (FE EU/AU, FE 350 S US)
13
Engine Number
13
Fork Part Number
13
Shock Absorber Article Number
14
Motorcycle
15
Raising the Motorcycle with a Lift Stand
15
Lift Stand
15
Starting
15
Starting the Motorcycle for a Check
16
Fork, Triple Clamp
17
Adjusting the Compression Damping 9 of the Fork
17
Adjusting the Rebound Damping of 9.1 the Fork
17
Bleeding the Fork Legs
18
Cleaning the Dust Boots of the Fork Legs
18
Removing the Fork Legs
19
Installing the Fork Legs
19
Removing the Fork Protector
21
Installing the Fork Protector
21
Performing a Fork Service
21
Disassembling the Fork Legs
22
Removing the Spring
24
Disassembling the Cartridge
25
Disassembling the Piston Rod
26
Disassembling the Hydrostop Unit
27
Disassembling the Seal Ring Retainer
28
Checking the Fork Legs
28
Assembling the Seal Ring Retainer
30
Assembling the Hydrostop Unit
30
Assembling the Piston Rod
31
Assembling the Cartridge
32
Assembling the Fork Legs
34
Lubricating the Steering Head Bearing
38
Removing the Lower Triple Clamp
39
Installing the Lower Triple Clamp
40
Checking the Play of the Steering Head Bearing
42
Changing the Steering Head Bearing
43
Adjusting the Steering Head Bearing Play
44
7 Handlebar,Controls
46
Handlebar Position
46
Adjusting the Handlebar Position
46
Adjusting the Basic Position of the Clutch Lever
47
Checking the Routing of the Throttle Cable
47
Checking the Play in the Throttle Cable
48
Adjusting the Play in the Throttle Cable
49
Frame
50
Removing the Engine Guard
50
Installing the Engine Guard
50
Checking the Frame
50
Shock Absorber, Swingarm
51
Adjusting the High-Speed Compression Damping of the Shock Absorber
51
Adjusting the Low-Speed Compression Damping of the Shock Absorber
51
Adjusting the Rebound Damping of the Shock Absorber
52
Measuring Rear Wheel Sag Unloaded
53
Checking the Static Sag of the Shock Absorber
53
Checking the Riding Sag of the Shock Absorber
54
Shock Absorber
54
Adjusting the Riding Sag
55
Removing the Shock Absorber
56
Installing the Shock Absorber
57
Checking the Shock Absorber Linkage
57
Servicing the Shock Absorber
59
Removing the Spring
60
Disassembling the Damper
61
Disassembling the Piston Rod
62
Disassembling the Seal Ring Retainer
63
Changing the Pilot Bushing
64
Checking the Damper
65
Removing the Heim Joint
66
Installing the Heim Joint
67
Assembling Seal Ring Retainer
67
Assembling the Piston Rod
68
Assembling the Damper
70
Bleeding and Filling the Damper
72
Filling Damper with Nitrogen
75
Installing the Spring
76
Checking the Swingarm
77
Checking the Swingarm Bearing for Play
77
Removing the Swingarm
79
Installing the Swingarm
80
Changing the Swingarm Bearing
81
Exhaust
85
Removing the Manifold
85
Installing the Manifold
87
Removing the Main Silencer
89
Installing the Main Silencer
89
Changing the Glass Fiber Yarn Filling in the Main Silencer
90
Spark Arrestor, Cleaning
92
11 Air Filter
94
Removing the Air Filter Box Cover
94
Installing the Air Filter Box Cover
94
Removing the Air Filter
94
Installing the Air Filter
95
Cleaning the Air Filter and Air Filter Box
95
Sealing the Air Filter Box
96
Fuel Tank, Seat, Trim
97
Opening the Filler Cap
97
Closing the Filler Cap
98
Removing the Right Side Cover
98
Installing the Right Side Cover
98
Removing the Seat
99
Mounting the Seat
99
Removing the Fuel Tank
100
Installing the Fuel Tank
102
Changing the Fuel Screen
103
Changing the Fuel Filter
105
Changing the Fuel Pump
107
Checking the Fuel Pressure
109
Removing the Activated Charcoal Filter (FE 350 S US)
110
Installing the Activated Charcoal Filter (FE 350 S US)
111
13 Mask, Fender
113
Removing Front Fender
113
Installing Front Fender
114
Removing the Headlight Mask with the Headlight
115
Installing the Headlight Mask with the Headlight
116
14 Wheels
119
Checking the Tire Air Pressure
119
Checking the Tire Condition
119
Checking the Wheel Bearing for Play
120
Checking the Brake Discs
121
Checking Spoke Tension
121
Checking the Rim Run-Out
122
Front Wheel
123
Removing the Front Wheel
123
Installing the Front Wheel
124
Changing the Front Brake Disc
125
Changing Front Wheel Bearing
125
Rear Wheel
127
Removing the Rear Wheel
127
Installing the Rear Wheel
128
Changing the Rear Brake Disc
130
Checking the Chain Tension
131
Adjusting the Chain Tension
131
Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
133
Checking for Chain Dirt Accumulation
135
Cleaning the Chain
135
Changing the Drivetrain Kit
136
Changing the Rear Wheel Bearing
138
15 Wiring Harness, Battery
142
Changing the Fuses of Individual Power Consumers
142
Changing the Main Fuse
144
Checking the Starter Relay
145
Removing the Battery
145
Installing the Battery
146
Recharging the Battery
147
Checking the Charging Voltage
148
Checking the Open-Circuit Current
148
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 the Basic Position of the Hand Brake Lever (FE 350 US)
153
Adjusting Free Travel of Hand Brake Lever (FE EU/AU, FE 350 S 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
177
Engine Disassembly
183
Preparations
183
Removing the Clutch Push Rod
183
Removing the Spacer
183
Draining the Engine Oil
183
Removing the Oil Filter
184
Removing the Spark Plug
184
Removing the Valve Cover
185
Removing the Alternator Cover
185
Removing the Torque Limiter
186
Positioning the Engine at Ignition Top Dead Center
186
Removing the Timing Chain Tensioner
186
Removing the Camshaft
187
Removing the Cylinder Head
187
Removing the Piston
188
Removing the Starter Drive
188
Removing the Suction Pump
190
Removing the Water Pump Wheel
191
Removing the Clutch Cover
191
Removing the Clutch Discs
191
Removing the Clutch Basket
192
Removing the Shift Shaft
193
Removing the Shift Drum Locating Unit
193
Removing the Locking Lever
194
Removing the Force Pump
194
Removing the Primary Gear
195
Removing the Timing Chain
195
Removing the Spacer
195
Removing the Left Section of the Engine Case
196
Removing the Shift Rails
196
Removing the Shift Drum
197
Removing the Shift Forks
197
Removing the Transmission Shafts
197
Removing the Crankshaft
198
Working on Individual Parts
198
Work on the Right Section of the Engine Case
198
Working on the Left Section of the Engine Case
200
Work on the Clutch Cover
201
Checking the Oil Pressure Regulator Valve
203
Checking the Lubrication System
204
Removing the Crankshaft Bearing Inner Race
204
Installing the Crankshaft Bearing Inner Race
205
Changing the Connecting Rod, Conrod Bearing and Crank Pin
205
Checking the Crankshaft Run-Out at the Bearing Pin
207
Measuring the Crankshaft End Play
207
Removing the Drive Wheel of the Balancer Shaft
208
Installing the Drive Wheel of the Balancer Shaft
208
Cylinder - Nikasil ® Coating
208
18.4.14 Checking/Measuring the Cylinder
208
Checking/Measuring the Piston
209
Measuring the Piston/Cylinder Mounting Clearance
210
Checking the Piston Ring End Gap
210
Changing the Camshaft Bearing
211
Checking the Camshafts
211
Checking the Pivot Points of the Camshafts
212
Removing the Valves
213
Checking the Valves
214
Checking the Valve Springs
214
Checking the Valve Spring Seat
214
Checking the Cam Levers
215
Checking the Cylinder Head
215
Installing the Valves
216
Checking the Freewheel
217
Removing the Freewheel
217
Installing the Freewheel
218
Checking the Electric Starter Drive
219
Checking the Timing Assembly
220
Preparing the Timing Chain Tensioner for Installation
221
Checking the Clutch
222
Checking the Shift Mechanism
223
Preassembling the Shift Shaft
224
Disassembling the Main Shaft
225
Disassembling the Countershaft
226
Checking the Transmission
226
Assembling the Main Shaft
228
Assembling the Countershaft
229
Engine Assembly
230
Installing the Crankshaft
230
Installing the Transmission Shafts
230
Installing the Shift Forks
231
Installing the Shift Drum
231
Installing the Shift Rails
231
Installing the Left Engine Case
232
Installing the Spacer
233
Installing the Timing Chain
233
Installing the Primary Gear
234
Installing the Force Pump
234
Installing the Suction Pump
235
Installing the Locking Lever
236
Installing the Shift Drum Locating Unit
236
Installing the Shift Shaft
236
Installing the Clutch Basket
236
Installing the Clutch Discs
237
Installing the Clutch Cover
239
Installing the Water Pump Cover
240
Installing the Starter Drive
241
Installing the Piston
242
Installing the Cylinder Head
244
Installing the Camshafts
245
Checking the Valve Timing
246
Adjusting the Valve Timing
246
Installing the Timing Chain Tensioner
248
Checking the Valve Clearance
249
Adjusting the Valve Clearance
250
Installing the Torque Limiter
250
Installing the Alternator Cover
250
Installing the Valve Cover
251
Installing the Spark Plug
251
Installing the Oil Filter
252
Installing the Oil Screen
252
Installing the Spacer
253
Installing the Clutch Push Rod
253
Removing the Engine from the Engine Assembly Stand
253
19 Clutch
254
Checking/Correcting the Fluid Level of the Hydraulic Clutch
254
Changing the Hydraulic Clutch Fluid
255
20 Water Pump, Cooling System
257
Cooling System
257
Checking the Antifreeze and Coolant Level
257
Checking the Coolant Level
258
Draining the Coolant
259
Refilling Coolant
260
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
264
Checking the Engine Oil Pressure
265
22 Ignition System
267
Ignition Coil - Checking the Secondary Winding
267
Checking the Spark Plug Connector
267
Alternator - Checking the Stator Winding
267
Removing the Stator and Ignition Pulse Generator
268
Installing the Stator and Ignition 30.11 Pulse Generator
269
23 Cylinder Head
270
Checking the Valve Clearance
270
Adjusting the Valve Clearance
273
24 Electric Starter
275
Checking the Starter Motor
275
25 Throttle Valve Body
276
Adjusting the Idle Speed
276
Executing the Initialization Run
276
26 Technical Data
278
Engine
278
Tolerance, Engine Wear Limits
279
Engine Tightening Torques
279
Capacities
281
Engine Oil
281
Coolant
281
Fuel
282
Chassis
282
Electrical System
283
Tires
283
Fork
283
Shock Absorber
284
Chassis Tightening Torques
284
27 Cleaning, Care
287
Cleaning the Motorcycle
287
Checks and Maintenance Steps for Winter Operation
288
28 Storage
289
Preparing for Use after Storage
290
29 Service Schedule
291
Service Work (as Additional Order)
292
30 Wiring Diagram
295
Eu)
296
Eu)
298
Eu)
300
Eu)
302
Eu)
304
Eu)
306
Eu)
308
Fe Au)
310
Fe Au)
312
Fe Au)
314
Fe Au)
316
Fe Au)
318
Fe Au)
320
Fe Au)
322
Fe Au)
324
Fe 350 Us)
326
Fe 350 Us)
328
Fe 350 Us)
330
Fe 350 Us)
332
Fe 350 Us)
334
Fe 350 Us)
336
Fe 350 S Us)
338
Fe 350 S Us)
340
Fe 350 S Us)
342
Fe 350 S Us)
344
Fe 350 S Us)
346
Fe 350 S Us)
348
Fe 350 S Us)
350
Fe 350 S Us)
352
Substances
354
32 Auxiliary Substances
356
33 Special Tools
358
Standards
374
35 List of Abbreviations
375
Index
376

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