Husqvarna 3403054en Manuals

Manuals and User Guides for Husqvarna 3403054en. We have 1 Husqvarna 3403054en manual available for free PDF download: Repair Manual

Husqvarna 3403054en Repair Manual (346 pages)

Brand: Husqvarna | Category: Motorcycle | Size: 37.72 MB

Table of Contents
4
Means of Representation
8
Symbols Used
8
Formats Used
8
Safety Advice
9
Repair Manual
9
Degrees of Risk and Symbols
9
Work Rules
9
Important Notes
10
Manufacturer and Implied Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Figures
10
Serial Numbers
11
Chassis Number
11
Type Label
11
Engine Number
11
Key Number
12
Fork Part Number
12
Shock Absorber Article Number
12
Motorcycle
13
Raising the Motorcycle with the Rear Lifting Gear
13
Removing the Rear of the Motorcycle from the Lifting Gear
13
Raising the Motorcycle with a Lift Stand
13
Removing the Motorcycle from the Lift Stand
14
Raising the Motorcycle with the Work Stand
14
Removing the Motorcycle from the Work Stand
14
Starting
15
Starting the Motorcycle to Check the Function
16
Fork, Triple Clamp
17
Adjusting the Compression Damping of the Fork
17
Adjusting the Rebound Damping of the Fork
17
Cleaning the Dust Boots of the Fork Legs
18
Removing the Fork Protector
19
Installing the Fork Protector
19
Removing the Fork Legs
19
Installing the Fork Legs
20
Performing a Fork Service
21
Disassembling the Fork Legs
21
Removing the Spring
23
Disassembling the Cartridge
23
Disassembling the Piston Rod
25
Disassembling the Hydrostop Unit
26
Disassembling the Seal Ring Retainer
26
Checking the Fork Legs
27
Assembling the Seal Ring Retainer
28
Assembling the Hydrostop Unit
28
Piston Rod, Assembling
29
Cartridge, Assembling
30
Assembling the Fork Legs
31
Checking the Play of the Steering Head Bearing
35
Adjusting the Steering Head Bearing Play
35
Removing the Lower Triple Clamp
36
Installing the Lower Triple Clamp
37
Changing the Steering Head Bearing
39
Handlebar, Controls
41
Handlebar Position
41
Adjusting the Handlebar Position
41
Changing the Throttle Grip
41
Frame
45
Removing the Engine Guard
45
Installing the Engine Guard
45
Checking the Frame
45
Shock Absorber, Swingarm
46
Adjusting the High-Speed Compression Damping of the Shock Absorber
46
Adjusting the Low-Speed Compression Damping of the Shock Absorber
46
Adjusting the Rebound Damping of the Shock Absorber
47
Measuring the Unloaded Rear Wheel Sag
48
Checking the Static Sag of the Shock Absorber
48
Checking the Riding Sag of the Shock Absorber
48
Adjusting the Spring Preload of the Shock Absorber
49
Adjusting the Riding Sag
50
Removing the Shock Absorber
50
Installing the Shock Absorber
52
Checking the Shock Absorber Linkage
53
Servicing the Shock Absorber
55
Removing the Spring
56
Dismantling the Damper
56
Disassembling the Piston Rod
58
Checking the Damper
59
Removing the Heim Joint
60
Installing the Heim Joint
60
Assembling the Piston Rod
61
Assembling the Damper
62
Bleeding and Filling the Damper
64
Filling the Damper with Nitrogen
67
Installing the Spring
68
Checking the Swingarm
68
Checking the Swingarm Bearing for Play
69
Removing the Swingarm
69
Installing the Swingarm
70
Changing the Swingarm Bearing
71
Checking the Heim Joint for Play
73
Changing the Heim Joint
73
Exhaust
76
Removing the Manifold
76
Installing the Manifold
77
Removing the Main Silencer
78
Installing the Main Silencer
78
Air Filter
80
Removing the Air Filter
80
Installing the Air Filter
80
Removing the Air Filter Box
80
Installing the Air Filter Box
82
Fuel Tank, Seat, Trim
84
Opening the Filler Cap
84
Closing Filler Cap
84
Removing the Seat
84
Mounting the Seat
85
Take off the Side Cover
85
Mounting the Side Cover
85
Removing the Rear Right Side Cover
86
Installing the Rear Right Side Cover
86
Removing the Rear Left Side Cover
87
Installing the Rear Left Side Cover
87
Removing the Rear Fairing
88
Fitting the Rear Fairing
88
Checking the Fuel Pressure
89
Changing the Fuel Screen
90
Changing the Fuel Filter
91
Changing the Fuel Pump
94
Mask, Fender
98
Removing the Front Fender
98
Installing the Front Fender
98
Wheels
99
Checking the Tire Air Pressure
99
Checking the Tire Condition
99
Checking the Wheel Bearing for Play
100
Checking the Brake Discs
100
Checking Spoke Tension
101
Checking the Rim Run-Out
101
Front Wheel
102
Removing the Front Wheel
102
Installing the Front Wheel
103
Removing the Front Wheel Using Work
103
Installing the Front Wheel Using a Work
104
Stand
104
Changing the Front Brake Disc
105
Changing the Front Wheel Bearing
105
Rear Wheel
106
Removing the Rear Wheel
106
Removing the Rear Wheel Using a Work Stand
107
Removing the Rear Wheel Using a Work
108
Stand
108
Changing the Rear Wheel Bearing
109
Changing the Bearing of the Rear Sprocket Carrier
111
Changing the Rear Brake Disc
112
Checking the Chain Tension
112
Adjusting the Chain Tension
113
Adjusting the Chain Guide
114
Checking the Chain, Rear Sprocket, Engine
114
Opening the Chain
116
Riveting the Chain
116
Cleaning the Chain
117
Checking the Rear Hub Rubber Dampers
117
Changing the Drivetrain Kit
118
Wiring Harness, Battery
120
Removing the Battery
120
Installing the Battery
121
Disconnecting the Battery
121
Connecting the Battery
122
Recharging the Battery
123
Checking the Charging Voltage
124
Checking the Open-Circuit Current
125
Changing the Main Fuse
126
Changing the Fuses of Individual Power Consumers
127
Adjusting the Engine Characteristic
128
Brake System
129
Checking the Front Brake Linings
129
Changing the Front Brake Linings
129
Adjusting the Basic Position of the Hand Brake Lever
131
Checking Brake Fluid Level of Front Brake
131
Adding Front Brake Fluid
131
Changing the Front Brake Fluid
132
Checking the Rear Brake Linings
134
Changing the Rear Brake Linings
134
Checking the Free Travel of Foot Brake Lever
136
Adjusting the Basic Position of the Foot Brake
136
Lever
136
Checking the Rear Brake Fluid Level
136
Adding Rear Brake Fluid
137
Changing the Rear Brake Fluid
138
Lighting System, Instruments
141
Combination Instrument
141
Setting the Kilometers or Miles
141
Setting the Clock
141
Setting Wheel Circumference
141
Checking the Headlight Setting
142
Adjusting the Headlight Range
142
Removing the Headlight Mask with the Headlight
143
Installing the Headlight Mask with the Headlight
143
Changing the Parking Light Bulb
144
Changing the Headlight Bulb
144
Changing the Turn Signal Bulb (US)
145
Removing the Engine
146
Installing the Engine
150
Engine Disassembly
154
Clamping the Engine into the Engine Assembly Stand
154
Draining the Engine Oil
155
Removing the Clutch Push Rod
155
Removing the Starter Motor
155
Removing the Spark Plugs
155
Removing the Valve Cover
156
Removing the Alternator Cover
156
Removing the Spacer
156
Removing the Gear Position Sensor
156
Removing the Oil Filter
157
Removing the Thermostat
157
Positioning the Engine at Ignition Top Dead Center
158
Removing the Timing Chain Tensioner
158
Removing the Camshafts
159
Removing the Cylinder Head
160
Removing the Piston
161
Removing the Water Pump Impeller
162
Removing the Rotor
162
Removing the Timing Chain
163
Removing the Ignition Pulse Generator
163
Removing the Clutch Cover
164
Removing the Spacer and Spring
164
Removing the Clutch Basket
164
Removing the Primary Gear
166
Removing the Starter Drive
166
Removing Shift Shaft
167
Removing Shift Drum Locating
167
Removing Locking Lever
167
Removing the Oil Pumps
168
Removing the Left Engine Case
169
Removing the Crankshaft and Balancer Shaft
169
Removing the Transmission Shafts
169
Working on Individual Parts
170
Working on the Right Section of the Engine Case
170
Working on the Left Section of the Engine Case
172
Working on the Clutch Cover
173
Removing the Crankshaft Bearing Inner Race
174
Removing the Drive Wheel of the Balancer Shaft
174
Changing the Connecting Rod, Conrod Bearing, and Crank Pin
174
Checking Crankshaft Run-Out at Bearing
176
Installing the Drive Wheel of the Balancer Shaft
176
Installing the Crankshaft Bearing Inner Race
177
Measuring Axial Clearance of Crankshaft and Balancer Shaft
177
Cylinder - Nikasil® Coating
178
Checking/Measuring the Cylinder
178
Checking/Measuring the Piston
179
Checking Piston Ring End Gap
180
Determining the Piston/Cylinder Mounting Clearance
180
Checking the Oil Pumps for Wear
180
Changing the Autodecompressor
181
Preparing Timing Chain Tensioner for Installation
183
Checking the Timing Assembly
184
Demounting Cam Lever and Rocker Arm
184
Changing Camshaft Bearing and Balancer Shaft Bearing
185
Checking the Valves
189
Removing the Valves
189
Checking Valve Springs
190
Checking Valve Spring Retainer
190
Checking the Cylinder Head
190
Installing Cam Lever and Rocker Arm
191
Disassembling the Antihopping Clutch
192
Checking the Clutch
193
Preassembling the Antihopping Clutch
194
Checking the Shift Mechanism
195
Preassembling the Shift Shaft
196
Disassembling the Main Shaft
197
Disassembling the Countershaft
198
Checking the Transmission
198
Assembling the Main Shaft
200
Assembling the Countershaft
201
Checking the Starter Drive
202
Freewheel, Removing
203
Checking Freewheel
203
Freewheel, Installing
203
Engine Assembly
204
Installing the Transmission Shafts
204
Installing Crankshaft and Balancer Shaft
205
Installing the Left Engine Case
206
Installing the Oil Pumps
206
Installing Locking Lever
207
Installing Shift Drum Locating
208
Installing Shift Shaft
208
Installing the Starter Drive
208
Installing the Primary Gear
209
Installing the Clutch Basket
209
Installing the Spacer and Spring
211
Installing the Clutch Cover
211
Installing the Ignition Pulse Generator
211
Installing Timing Chain and Timing Chain Sprocket
212
Installing the Timing Chain Rails
212
Installing the Rotor
213
Adjusting Crankshaft Position Sensor Distance
213
Setting Engine to Top Dead Center
214
Mounting the Water Pump Cover
214
Installing the Piston
214
Installing the Cylinder Head
217
Installing the Camshafts
218
Installing the Timing Chain Tensioner
219
Checking the Valve Clearance
220
Adjusting the Valve Clearance
221
Installing the Thermostat
223
Installing the Oil Filter
223
Installing the Gear Position Sensor
224
Installing the Spacer
224
Installing the Alternator Cover
225
Installing Oil Screens
225
Installing the Starter Motor
226
Installing the Valve Cover
226
Installing the Spark Plugs
226
Removing the Engine from the Engine Assembly Stand
226
Checking/Correcting the Fluid Level of the Hydraulic Clutch
227
Changing the Hydraulic Clutch Fluid
227
Checking the Clutch
228
Shift Mechanism
235
Changing the Gear Position Sensor
235
Programming the Gear Position Sensor
236
Water Pump, Cooling System
237
Draining the Coolant
237
Filling/Bleeding the Cooling System
237
Checking the Antifreeze and Coolant Level
238
Checking the Coolant Level
239

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Husqvarna 3403054en Repair Manual (346 pages)

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