Husqvarna NUDA 900 2012 Page 65 Workshop Manual Download

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E.5

NUDA 900 2012/2013 - NUDA 900 R 2012/2013

H10662

H10663

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

Saddle removal

Turn the pin (1) around 90° counter-clockwise and remove the saddle (2) to the

rear part unhooking it from the front brackets.

Summary of Contents for NUDA 900 2012

Page 1: ...NUDA 900 2012 2013 NUDA 900 R 2012 2013 Workshop Manual Ed 11 2011 Rev 02 ...

Page 2: ...3 10 2012 Section L Valid only for MY12 no ABS version 02 23 10 2012 Section L1 Valid only for MY13 ABS version 02 08 11 2012 M 18 H10939 modificed drawing in H12123 02 08 11 2012 M 21 H10942 modificed drawing in H12124 02 23 10 2012 M 28 Delete note HUSQVARNA MOTORCYCLES S R L Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to ref...

Page 3: ...Workshop Manual Ed 11 2011 FOREWORD TABLE OF CONTENTS 1st edition 11 2011 Rev 02 Printed in Italy MODELS COVERED from serial number onwards Copyright by HUSQVARNA MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop Manual 1 Chassis serial number ...

Page 4: ... photographs are provided next to the text Notes with special significance are identified as follows throughout the manual Accident prevention rules for operator and persons working nearby Damage to vehicle and or its components may result from incompliance with relevant instructions Additional information concerning the operation covered in the text Useful tips To prevent problems and ensure effe...

Page 5: ...General Information A Maintenance B Troubleshooting C Settings and Adjustments D General Procedures E Egine settings and adjustments F General engine procedures F1 Cylinder head removal disassembly F2 Crankcase disassembly F3 Engine torque figures F4 Wear limits of engine parts F5 Front Suspension I Rear Suspension J Brakes NON ABS Version MY12 ONLY L Brakes ABS Version MY13 ONLY L1 Electrical Sys...

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Page 7: ...b 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 b Workshop Manual Ed 11 2011 IMPORTANT NOTICES Section ...

Page 8: ...e environment Keep out of reach of children Do not tilt the vehicle excessively since this may cause fuel to leak Engine In some cases coolant may become inflammable and if burnt produce invisible flames which cause burns Do not spill coolant onto hot components like the engine or exhaust pipe etc since it may ignite During maintenance work wear latex gloves Never leave the coolant in open contain...

Page 9: ...ycling centres in accordance with the legal requirements in force in the country where the vehicle will be used Keep out of reach of children NUDA 900 and NUDA 900 R models are STREET LEGAL motorcycles they are guaranteed exempt from functional defects and covered with legal guarantee as far as the STANDARD CONFIGURATION IS MAINTAINED and the suggested maintenance table shown in Section B is obser...

Page 10: ...ng the reassembly make sure that the bearings turn freely without obstruction or without getting stuck otherwise replace them Always replace the seals the sealing rings the split pins the screws with damaged thread and the self locking nuts with new parts Use genuine HUSQVARNA parts and the recommended lubricant brands At the end of a repair or periodic maintenance test the vehicle before deliveri...

Page 11: ...A 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 A Workshop Manual Ed 11 2011 GENERAL INFORMATION Section ...

Page 12: ...brication A 3 Ignition A 3 Fuel system A 3 Primary drive A 3 Clutch A 3 Transmission A 3 Secondary drive A 4 Final ratios A 4 Chassis A 4 Front suspension A 4 Rear suspension A 4 Front brake A 4 Rear brake A 5 Rims A 5 Tyres A 5 Weight capacity A 5 Table for lubrication supplies A 5 Electrical components location A 6 Dimension A 7 ...

Page 13: ...33 mm Exhaust 0 0118 0 0161 in 0 30 0 41 mm Lubrication type dry sump oil circuit with built in tank cartridge filter and oil water heat exchanger Ignition type Electronic with adjustable advance digital control Spark plug type NGK LMAR8C 9 Spark plug electrode gap 0 0315 0 0354 in 0 8 0 9 mm Fuel system type Electronic injection feed Primary drive Drive gear on crankshaft Z 35 Driven gear on clut...

Page 14: ... 4 896 Chassis type tubular steel trellis with removable steel rear chassis Front suspension NUDA 900 Type upside down hydraulic fork 1 89 in ø 48 mm legs Wheel travel 8 27 in 210 mm NUDA 900 R Type upside down hydraulic fork adjustable compression rebound and spring reload ø 1 89 in ø 48 mm legs Wheel travel 8 27 in 210 mm Rear suspension NUDA 900 Type direct with hydraulic monoshock adjustable s...

Page 15: ...7 U S Gall 1 4 l Transmission oil Oil and oil filter replacement 0 73 imp Gall 0 87 U S Gall 3 3 l Oil replacement 0 7 Imp Gall 0 85 U S Gall 3 2 l Oil top up between minimum and maximum level 0 09 Imp Gall 0 11 U S Gall 0 4 l Table for lubrication supplies Engine gearbox and primary drive lubricating oil 1 CASTROL POWER1 RACING SAE 5W 40 2 SAE rating 15W 40 API SG SH JASO MA Engine coolant CASTRO...

Page 16: ... body Voltage regulator on a support on the battery Crankshaft position sensor on the right hand side of the engine The electrical system includes the following elements 12V 12Ah battery in the central part Turning indicator flasher integrated in the digital instrument Relay for fuel pump general relay and fan positioned on the front part in front of the control unit Electric fan Secondary fuses p...

Page 17: ...kshop Manual Ed 11 2011 GENERAL INFORMATION Dimension Wheelbase 58 86 in 1495 mm Overall length 86 22 in 2190 mm Overall width 35 16 in 893 mm Max height 48 03 in 1220 mm A Seat height NUDA 900 34 25 in 870 mm A Seat height NUDA 900 R 34 45 35 04 in mm 875 890 Min ground clearance 7 68 in 195 mm ...

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Page 19: ...B 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 B Workshop Manual Ed 11 2011 MAINTENANCE Section ...

Page 20: ...he first 1 000 Km EVERY 10 000 Km EVERY 20 000 Km EVERY 30 000 Km EVERY 40 000 Km Check engine oil level X X X X X EVERY 1 000 Km Replace engine oil together with oil filter clean magnetic plug M24x2 X X X X X EVERY 10 000 Km or ONCE A YEAR Check adjust valve play X X EVERY 20 000 Km Replace spark plugs X X EVERY 20 000 Km Check coolant level X EVERY 1 000 Km Replace coolant X X EVERY 20 000 Km or...

Page 21: ... X L X L X L X L X L Transmission cables and controls X X X Steering bearings and steering clearance X X X Wheel bearings X X Control unit diagnosis X X X X X Brake discs X X X X X X Front fork X X Rear shcok absorber X X General vehicle operation X X X Cooling system X X X Braking systems X X X Lights X X X Safety switches X X X X X Brake fluid 2 X X X X X X Coolant 2 X X X X X X Light alignment ...

Page 22: ......

Page 23: ...C 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 C Manuale d officina Ed 11 2011 TROUBLESHOOTING Section ...

Page 24: ...rk plugs fouled or wet Clean or exchange Battery nearly discharged starting rpm too low Check replace battery and check con nections check if battery is charged by generator Fuel supply inadequate Check fuel tank if empty Check replace fuel filter fuel supply pi pes fuel pump fuel pressure sensor and injectors Valve clearance below specification Adjust valve clearance according to spe cification V...

Page 25: ...ary For other possible causes see also Engine starts over but does not start engine or starts hard Engine has no or insufficient performance Leak air intake system leaking Check replace intake socket Spark plugs not according to specifications or defective Replace spark plug Valve clearance not according specifica tion Adjust valve clearance according to spe cification Valve timing incorrect Adjus...

Page 26: ...e taining ring for oil pump gear not fitted oil circuit blocked Exchange oil pump or oil pump gears assemble retaining ring for oil pump gear clean oil circuit Cylinder head gasket defective Exchange cylinder head gasket Leak air Check replace intake socket Engine temperature is too low Thermostat defective Replace thermostat Engine produces excessive blue smoke or engine uses too much oil Too muc...

Page 27: ...g into inside of engine leakage of oil pressure circuit Replace ignition cover gasket and tighten ignition cover with correct touque Oil pump worn Replace oil pump Oil diluted with fuel Piston rings and or cylinder bore worn Exchange piston rings and or cylinder Oil diluted with fuel motocycle is only used in short distances Use motorcycle at long distances in between Oil sieve oil filter dirty bl...

Page 28: ...pin bore or piston pin Piston rings broken or ring grooves worn Replace piston rings broken or ring groo ves Noiseseemstocomefromthecrankshaft or balancing swing arm or crankcase Bearings of crankshaft or conrods worn Replacecrankshaftand orconrodbearings and or replace crankshaft and conrods Needle bushing and or bearings of balan cing swing arm and or balancing rod worn Replace balancing swing a...

Page 29: ...hift lever Function of index lever or index spring imperfect Check index lever and index spring and exchange if necessary Adjustment of gearshift pawl incorrect Checkandadjustpawlwichspring exchan ge if necessary Engagement teeth and or windows of ge arbox gears badly worn Exchange gears Gearshift forks are worn or bent Exchange gearshift forks Gearbox gears are worn or damaged Exchange gearshift ...

Page 30: ... fork legs Remove excess oil Fork oil viscosity too high Change Overinflated tyres Deflate Improperly set rear shock absorber Adjust Damping is too soft Insufficient oil in fork legs Top up Fork oil viscosity too low Change Weak fork springs Replace Weak rear shock absorber spring Replace Improperly set rear shock absorber Adjust Front rear wheel shakes Bent wheel rim Replace Worn wheel hub bearin...

Page 31: ...charge Cables running to voltage regulator im properly connected or shorted Connect correctly or replace Voltage regulator faulty Replace Faulty generator Replace Generator overcharges battery Voltage regulator faulty Replace Battery does not hold charge Battery terminals dirty Clean Faulty generator Replace Faulty battery Replace Starter motor does not start or slips Battery is flat Charge Contro...

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Page 33: ...D 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 D Workshop Manual Ed 11 2011 SETTINGS AND ADJUSTMENTS Section ...

Page 34: ... 9 Rear brake fluid level check D 10 Oil level check D 10 Engine oil replacement and cartridge filter replacement D 11 Coolant level check D 12 Coolant replacement D 12 Air filter check D 15 Chain adjustment D 16 Lubricating the chain D 17 Suspension D 18 Suspension settings summary tables D 18 Rear shock absorber D 20 Spring preload adjustment NUDA 900 D 21 Spring preload adjustment NUDA 900 R D ...

Page 35: ...DA 900 R 2012 2013 H10662 1 H10663 2 Workshop Manual Ed 11 2011 SETTINGS AND ADJUSTMENTS Saddle removal Turn the pin 1 counter clockwise at approx 90 and remove the saddle 2 to the rear part unhooking it from the front brackets ...

Page 36: ...emoval Insert the key in the lock and remove the cap 1 Remove the screw 2 under the cap Loosen the five screws 3 that fasten the cover 4 and remove it Reinstall the reservoir cap 1 to prevent that objects from accidentally falling into it During the reassembly position correctly the bushings 5 ensur ing the that longest screws 3a are tightened in the rear part of the cover ...

Page 37: ...centre part of the side Throttle cable adjustment To check the correct adjustment of the throttle control cable operate as follows remove the reservoir and the filter box as outlined in the relevant sections turn throttle twistgrip 1 and make sure that there is a clearance of approx 2 mm 0 08 in if this does not work unlock the check nut 2 work on the nut 3 until you have about 2 mm clearance 0 08...

Page 38: ...2 Do not forget to tighten the screws 2 after adjusting Front brake control The brake control lever 1 is located on the right hand side of the handlebar Position adjustment The position of the control on the handlebar can be adjusted by loosening the two retaining screws 2 After adjustment turn the handlebar as far as possible to the right and make sure that the lever does not touch the bodywork A...

Page 39: ...e of the fluid level will let air into the system hence an extension of the lever stroke If the brake lever feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Too much brake lever free play may reduce braking action CHECK BRAKE PAD THICKNESS see Section L Do not spill brake fluid onto any painted surface or lens for examp...

Page 40: ...e to the left and make sure that the lever does not touch the bodywork Do not forget to tighten the screws 2 after adjusting Clutch control lever distance adjustment The lever 1 distance on the handlebar can be adjusted according to the size of the rider s hand To adjust the lever distance 1 from the handgrip push the lever 1 outwards and hold it in position then work on the adjuster screw as expl...

Page 41: ...tment Before staring the braking action rear brake pedal 1 shall have a free play B of 5 10 mm 0 196 0 39 in Should this not happen operate as follows Loosen the nut 2 Operate the master cylinder linkage 3 to increase or decrease free play Tighten the nut 2 at the end of the operation When the free play requirement is not met the brake pads will be subjected to an early wear that may lead to TOTAL...

Page 42: ...e brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Oil level check Start vehicle as described in the relevant section let it run for approx 3 min utes so as to warm engine up Stop the engine Keeping the motorbike upright and on even gr...

Page 43: ...g 2 drain the exhausted oil and clean magnet on plug 2 using a suitable tool unscrew the cartridge filter 3 and remove it replace the filter 3 with a new one and clean the contact surfaces between the filter and the crankcase before screwing it up lubricate the seal with en gine oil and hand tighten it screw the drainage plug 2 up again and replace the seal pour the recommended quantity of oil int...

Page 44: ...he relevant sections Do not remove the radiator cap 2 since all the liquid in the expan sion tank 1 will flow out Remove the cap 3 and add the fluid needed to restore the level to the ex pansion tank 1 for the type of liquid to use see the section Technical data Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water Coolant replacement Put the motorb...

Page 45: ...ipe 3 that connects the radiator 4 to the exchanger 5 Remove the exchanger pipe 3 and let the coolant drain in the bucket dur ing the reassembly replace the seal 6 Open the clamps 7 and remove the pipes 8 from the radiator allowing the coolant to drain fully from the radiator Reassemble all previously removed components in the reverse order Put the motorbike on the side stand ...

Page 46: ...upper bor der Refit the radiator cap 9 Start the engine and leave it on until the radiator is warm then turn off the engine and leave it to cool down for around 2 3 minutes Turn the radiator cap 9 until the 1st safety notch and let the possible pres sure discharge then remove the cap Top up with coolant until the maximum level of the radiator cap upper bor der Restart the engine and repeat the pro...

Page 47: ...nect connector 1 of the air temperature sensor Unscrew the two screws 2 that fasten the side panels at the front Unscrew the screws 3 on the filter cover 4 and remove it Clean the area around the filter 5 before removing it Remove the filter 5 check that it is not clogged and replace if necessary Before refitting the filter check that the contact surfaces between the filter the filter box and the ...

Page 48: ... 25 30 mm 0 984 1 181 in When the vehicle is running the chain must not hit the bottom part of the slider 2 If this is not the case proceed as follows make sure that the motorcycle is fully upright on the special rear support stand optional on the left side loosen the locking nut 3 of the wheel axle loosen the check nuts 5 on both chain tensioners turn the adjuster screws 4 to obtain the correct t...

Page 49: ...ease helps to accumulate dust and mud which act as abrasive and help to rapidly wear out the chain the front and rear sprockets Do not wash the chain with high pressure water jets and do not use harsh or highly flammable solvents After washing the chain using special detergent dry it and lubricate with suit able spray grease The chain lubricant must NOT come into contact with the tyres or the rear...

Page 50: ...djustments must be made on the front fork and the rear shock absorber as described in the following tables Suspension settings summary tables SHOCK ABSORBER NUDA 900 NUDA 900 with panniers and passenger NUDA 900 R NUDA 900 R Motard NUDA 900 R with panniers and passenger Length of shock absorber A 380 mm 14 96 in 385 mm 15 15 in 380 mm 14 96 in Shock absorber compression adjustment 16 clicks 14 cli...

Page 51: ... 0 R M o t a r d A 3 8 0 m m N U D A 9 0 0 A 3 8 0 m m N U D A 9 0 0 R Workshop Manual Ed 11 2011 SETTINGS AND ADJUSTMENTS NOTE Fork springs and shock absorbers with varying degrees of stiffness are available above all for use with passenger and or panniers NOTE Do not go beyond 385 mm ...

Page 52: ...following table SHOCK ABSORBER NUDA 900 NUDA 900 with panniers and passenger NUDA 900 R NUDA 900 R Motard NUDA 900 R with panniers and passenger Length of shock absorber A 380 mm 14 96 in 385 mm 15 15 in 380 mm 14 96 in Shock absorber compression adjustment 16 clicks 14 clicks 16 clicks Shock absorber rebound adjustment 25 clicks 10 clicks 18 clicks 9 clicks 18 clicks Shock absorber spring constan...

Page 53: ...e fuel tank as described in the relevant paragraph Clean the lock ring nut 1 and adjuster ring nut 2 on the spring 3 and the threading on the body of the shock absorber Loosen lock ring nut using a hook spanner Turn adjuster ring nut until reaching the desired position After having adjusted the suspension based on your weight and riding style tighten lock ring nut tightening torque 10 Nm 1 02 Kgm ...

Page 54: ...ster ring nut 2 on the spring 3 and the threading on the body of the shock absorber 2 Either with a hook wrench or an aluminium punch loosen the lock ring nut 3 Turn the adjuster ring nut as required 4 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 10 Nm 1 Kgm 7 38 ft lb Be careful not to touch hot exhaust pipe while adjusting the shock ab...

Page 55: ...e shock absorber 2 to the chassis Move the shock absorber 1 from the chassis loosen the nut 3 then turn the eyelet terminal 5 to adjust the length NOTE At each full turn of the eye terminal the length varies by 1 mm 0 04 in After the length adjustment tighten the nut 3 The maximum allowed length of the shock absorber between the eyelet terminal axle and the lower fork axle is 385 mm 15 16 in Do no...

Page 56: ... smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action Nuda 900 R The shock absorber has adjustable hydraulic compression and rebound damping A COMPRESSION Standard setting Adjuster 2 16 clicks 2 clicks B REBOUND Standard setting Adjuster 3 18 clicks 2 clicks To reset the standard setting turn the lower adjuster screw 2 and the upper adjuster screw ...

Page 57: ...icks To reset standard calibration turn adjuster screw B clockwise to reach the fully closed position and then turn it back the number of clicks specified above Turn the adjuster screw clockwise to increase rebound damping or counter clockwise to decrease it Never force the adjusting screws beyond the maximum open and closed positions c PRELOAD ADJUSTMENT To adjust turn the central nut C on the ca...

Page 58: ...the saddle the right hand side as outlined in the relevant sections Open the clamp 2 and disconnect the hose 1 from the coupling 3 Cut the clamp 4 Remove the filter box as described in the relevant section Open the clamp 5 and disconnect the hose 1 During the reassembly make sure that the clamp 4 is positioned on the rubber protection and that the hose 1 goes under the protection bracket 6 During ...

Page 59: ...e single components by disassembling the exhaust system Moreover check the tightening of the flanges nuts 1 that fasten the manifold to the cylinder head and of the fastening clamp 2 of the silencer to the mani fold as well as the tightening of the screw 3 that retains the silencer to its support The damaged or broken parts must be replaced Idle speed adjustment The idle speed is pre set by the co...

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Page 61: ...E 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 E Workshop Manual Ed 11 2011 GENERAL PROCEDURES Section ...

Page 62: ...nt turning indicator removal E 15 Combined dashboard removal E 16 Front mudguard removal E 17 Front mudguard fin removal E 18 Battery removal E 19 Reservoir removal E 20 Fuel pump removal E 22 Fuel pump inspection E 23 Filter box removal E 24 Throttle body removal E 26 Exhaust system removal E 27 Exhaust system removal E 28 Lambda sensor removal E 30 Coil Stick Coil removal and spark plug test E 3...

Page 63: ...and removal replacement Loosen the nut 1 and remove the rotary type switch 2 Release the spring 3 Loosen the screw 4 and remove the stand 5 During the reassembly grease the screw 4 and reassemble correctly the bushing 6 The screw 4 must be replaced at every disassembly NOTE For the correct installation of the rotatory type switch 2 refer to chapter M ...

Page 64: ...00 2012 2013 NUDA 900 R 2012 2013 H10726 7 8 H10728 8 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Stand foot replacement Loosen the screw 7 and replace the foot 8 by reinstalling it exactly as the figure shows ...

Page 65: ...3 NUDA 900 R 2012 2013 H10662 1 H10663 2 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Saddle removal Turn the pin 1 around 90 counter clockwise and remove the saddle 2 to the rear part unhooking it from the front brackets ...

Page 66: ...moval Insert the key in the lock and remove the cap 1 Remove the screw 2 under the cap Loosen the five screws 3 that fasten the cover 4 and remove it Reinstall the reservoir cap 1 to prevent objects from accidentally falling into it During the reassembly correctly position the bushings 5 ensuring the that longest screws 3a are tightened in the front part of the cover ...

Page 67: ...e procedures to remove the left hand side During the reassembly tighten the screws with the respective bush ings and position the M6 screw 1a in the centre part of the side Number plate holder removal Remove the saddle as described in the relevant paragraph Disconnect the two connectors 1 and 2 of the rear harness Loosen the two screws 3 that fasten the number holder 4 to the chassis Remove the sa...

Page 68: ...DA 900 2012 2013 NUDA 900 R 2012 2013 H10732 7 7 H10733 4 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Remove the two upper screws 7 Tilt the number plate holder 4 to the right and to the left and remove it ...

Page 69: ... H10736 3 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Tail light removal Remove the number plate holder as described in the relevant paragraph Remove the O ring 1 that fasten the cables Loosen the two screws 2 with the related bushings and remove the tail light 3 ...

Page 70: ...val Remove the number plate holder as described in the relevant paragraph Remove the tail light as described in the relevant paragraph Loosen the two screws 1 that fasten the passenger handle 2 Remove the passenger handle 2 during the reassembly make sure that the bushings 3 of the retaining screws of the tail light are positioned in the related seats ...

Page 71: ...10741 7 H10742 6 6 8 9 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Loosen the four self tapping screws 4 Loosen the two screws 5 that retain the turning indicators 6 Remove the lower cover 7 Disconnect the two connectors 8 and 9 and remove the two turning indi cators 6 ...

Page 72: ... plate bulb holder 12 replace the harness 10 and reinstall it exactly in the same position by fastening it with the clamp 11 and passing it behind the tab 13 During the reassembly of the turning indicators make sure that the water discharge hole 14 faces downwards and that the connector of the right hand turning indicator is connected to the connector marked with a white adhesive tape of the bike ...

Page 73: ...1 H10747 1 H10748 2 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Tail removal Remove the saddle the sides and the number plate holder as described in the relevant paragraphs Loosen the five screws 1 and remove the tail 2 slipping it off towards the rear part ...

Page 74: ...E 14 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10749 1 H10750 2 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Front fairing removal Loosen the two screws 1 and remove the spoiler 2 ...

Page 75: ...t paragraph Disconnect the connector 1 of the left hand indicator and the connector 2 of the right hand indicator Loosen the screws 3 and fully remove the indicators 4 During the reassembly of the turning indicators make sure that the water discharge hole 5 faces downwards and that the connector of the right hand turning indicator is connected to the connector marked with a white adhesive tape of ...

Page 76: ...iring as described in the relevant paragraph Disconnect the connector 1 Remove the retaining clip 2 and remove the dashboard 3 During the reassembly insert the pins in the special rubbers and lock the dashboard with the special retaining clips After the replacement of the dashboard it is necessary to connect the diagnostic tool to the vehicle and follow the wizard ...

Page 77: ...Manual Ed 11 2011 GENERAL PROCEDURES Front mudguard removal Loosen the six screws 1 that fasten the mudguard 2 to the fork making sure to retain the bushings 3 Lift and slightly turn the mudguard 2 then remove it During the reassembly insert again correctly the bushings 3 on the mudguard 2 ...

Page 78: ...R 2012 2013 H10761 1 2 H10762 3 4 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Front mudguard fin removal Loosen the screw 1 and remove the fin 2 during the reassembly fit the tab 3 in the special seat 4 then tighten again the screw 1 ...

Page 79: ...sitive cable when reassembling first connect the RED positive cable then the BLACK or BLUE negative cable remove the battery 3 from its housing by easing it off from under the chassis beam Always check the battery charge before reinstalling it on the vehicle The battery should be kept clean and the terminals coated with neutral grease or petroleum jelly During the removal of the battery avoid any ...

Page 80: ... number plate holder and the tail as described in the relevant paragraphs Disconnect the oil pump supply connector 1 Loosen the two screws 2 and remove the pump delivery fitting 3 A small quantity of fuel can come out of the pipe Cut the clamp 4 that retains the fuel pipe 5 Move the fuel pipe 5 Remove the reservoir breather hose 6 from the cap flange 7 Loosen the reservoir centring screw 8 ...

Page 81: ...RES Loosen the four screws 9 two per side that fasten the small chassis 11 to the chassis 10 Remove the small chassis 11 with the reservoir 12 towards the rear side of the bike Loosen the two screws 13 one per side and remove the small chassis 11 from the reservoir 12 Loosen the screws 14 and remove the cap flange 7 During the reassembly replace the screws 9 ...

Page 82: ...l that could come out Use a suitable tool to loosen the ring nut 3 and remove the reservoir pump 4 Check the seal 5 for wear change it if dry or damaged During the reassembly make sure that the seal is in the correct position the lip with the greater diameter must be installed facing outwards Check the status of the O ring seals replace if damaged During the reassembly of the pump the reference ta...

Page 83: ... the positive pole 12V of the power supply to the pin of the red cable in the pump connector Connect the negative pole of the power supply to the negative pin in the pump connector Never keep the pump connected to the power supply unit for more than 3 seconds in a row HYDRAULIC DIAGRAM OUT REGULATOR FINE FILTER PUMP FUEL PRE FILTER ELECTRIC DIAGRAM FUEL SYSTEM GROUND SIGNAL GROUND GROUND FILTER ...

Page 84: ... box removal Remove the fuel tank as described in the relevant paragraph Disconnect and remove the connector 1 of the air temperature Disconnect the connector 2 of the idle air actuator Stepper motor Remove the two small tubes 3 of the idle air actuator Stepper motor on the throttle body Loosen the two nuts 4 that fasten the chassis ...

Page 85: ...10785 7 8 9 H10786 6 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Loosen the two front screws 5 Lift the filter box 6 Open the clamp 7 and remove the Blow By pipe 8 remove the filter box 6 During the reassembly the throttle control cable 9 must pass over the pipe 8 ...

Page 86: ...11 Throttle body removal Remove the reservoir and the filter box as described in the relevant para graphs Remove the throttle body 1 from the harness Disconnect the connector 2 from the injectors Disconnect the connector 3 of the TPS Disconnect the throttle control cable 4 Open the two clamps 5 Remove the throttle body 1 ...

Page 87: ...2012 2013 NUDA 900 R 2012 2013 H10925 1 2 3 4 5 6 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Exhaust system removal Key 1 Silencer 2 Clamp 3 Exhaust valve actuator starter motor 4 Lambda sensor 5 Manifold 6 Gasket ...

Page 88: ...aust system removal Remove the radiator and the reservoir as described in the relevant para graphs Remove the protection 1 by loosening the screws 2 Loosen the nuts 3 and disconnect the cables 4 that control the exhaust valve Loosen the screw 5 of the clamp 6 that fasten the silencer to the exhaust pipe 7 Loosen the screw 8 and remove the silencer 6 ...

Page 89: ...11 H10800 12 H10801 13 H10802 10 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Loosen the nuts 9 of the exhaust manifold 10 Disconnect the connector 11 of the Lambda sensor Cut the clamp 12 Loosen the central screw 13 of the manifold support 10 Remove the manifold 10 ...

Page 90: ...GENERAL PROCEDURES Workshop Manual Ed 11 2011 During the reassembly check the seals 14 for wear replace if damaged Lambda sensor removal Remove the fuel tank as described in the relevant paragraph Disconnect the connector 1 Cut the clamp 2 Unscrew the Lambda sensor 3 from the exhaust manifold ...

Page 91: ...t after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications Correct heat rating The tip of the insulator should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the spark plug has overheated and insulat...

Page 92: ... the horn 2 Radiator removal Remove the saddle and the right hand panel as described in the relevant paragraphs Drain the coolant as indicated in the relevant paragraph Use suitable pliers to open the clamps 1 that fasten the pipes 2 and 3 that connect the radiator engine Remove the two pipes 2 and 3 from the radiator Open the clamp 4 and remove the pipe 5 that connects the expansion tank to the r...

Page 93: ...15 7 H10816 8 H10817 9 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Loosen the screw 6 Cut the fan harness retaining clamp 7 Disconnect the connector 8 of the fan Remove the radiator 9 from the right hand side of the bike by removing it from the special clips ...

Page 94: ...reassembly make sure that the pins 10 and 11 fit in the support 12 and 13 respectively Electric fan removal Remove the radiator as described in the relevant paragraph Detach the two clips 1 that fasten the fan to the radiator 2 in the upper part Loosen the lower screw 3 and remove the fan Gearbox lever removal Loosen the screw 1 and remove the lever 2 ...

Page 95: ...oir the oil reservoir and the voltage regulator as described in the relevant paragraphs Loosen and remove the upper pin 1 of the shock absorber then tilt the shock absorber to the rear part of the bike Remove the connectors 2 3 and 4 from the battery housing Cut the clamps 5 that retain the harness Disconnect the connector 6 and detach the solenoid starter 7 from the support bracket ...

Page 96: ...rkshop Manual Ed 11 2011 Loosen the screw 8 in the right hand side the screw 9 in the left hand part and the two screws 10 in the rear part During the reassembly position again correctly the bushings 11 Keep the shock absorber lifted and turn the battery housing clockwise then remove it from the rear side ...

Page 97: ...chapters Filter box reservoir radiator with the respective pipes rear shock absorber and rear swinging arm front end forks yokes handlebar etc exhaust assembly Loosen the screws 1 the screw 2 unhook the spring 3 and remove the cover 4 Remove the la retaining pin 5 and detach the master cylinder 6 from the lever 7 Remove the left hand footrest 8 with the support by loosening the screws 9 During the...

Page 98: ...2012 2013 H10832 10 H10833 11 12 H10834 13 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Loosen the screw 10 on the left side and the screw 11 on the right side keeping the spacer 12 Disconnect from the engine the cable 13 of the clutch ...

Page 99: ... H10836 14 16 17 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Remove the harness 14 from the bike by cutting the retaining clamps Loosen the screws 15 from the left side and the screws 16 from the right side Lift the chassis 17 by removing it from the engine ...

Page 100: ... H10837 1 H10838 2 H10839 2 H10840 2 3 GENERAL PROCEDURES Workshop Manual Ed 11 2011 Engine reassembly Remove the battery support 1 from the engine by loosening the screws 2 Insert the new clamps 3 in the slots and reinstall the battery support 1 ...

Page 101: ...10843 5 Workshop Manual Ed 11 2011 GENERAL PROCEDURES Reinstall the chassis 4 on the engine and from the left hand side screw manually the screws 5 fully home without tightening then from the right hand side tighten manually the screws 6 fully home by interposing the related spacers 7 ...

Page 102: ...rews 5 on the left hand side of the chassis to torque Tighten the screws 6 on the right hand side of the chassis to torque Tighten the nut 9 of the swinging arm to torque Install in a sequence the following components as described in the relevant paragraphs chapters Left footrest Master cylinder with related cover Harness Exhaust assembly Front end Rear shock absorber radiator with relevant pipes ...

Page 103: ...F 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 Workshop Manual Ed 11 2011 ENGINE SETTINGS AND ADJUSTMENTS F Section Refer to chapter F4 for all engine tightening torques ...

Page 104: ...cking cylinder 2 valve clearance F 3 HALF BALL REPLACEMENT F 4 Locking the crankshaft F 4 Chain tensioner disassembly F 5 Camshaft mount disassembly F 5 Camshaft removal F 5 Half ball replacement F 5 CAMSHAFT ASSEMBLY F 6 Exhaust camshaft installation F 6 Intake camshaft installation F 6 Camshaft mount assembly F 7 TIMING CHECK F 9 Engine phasing F 10 Chain tensioner disassembly F 10 Camshaft moun...

Page 105: ...easurement Use a feeler gauge to measure valve clearance between the cam and the rocker arm Note down the measurements on a measurement sheet Technical specifications Intake valve clearance with cold engine max 35 C 0 23 0 33 mm 0 0091 0 013 in Exhaust valve clear ance with cold engine max 35 C 0 30 0 41 mm 0 0118 0 0161 in Checking cylinder 2 valve clearance Turn the crankshaft in the normal dire...

Page 106: ...al rotation direction until the marks IN and EX on the camshaft gears are facing each other and are positioned level with the sealing surface Locking the crankshaft Remove the screw 1 with the sealing ring 2 Check if the notch 3 arrow on the crank arm is visible through the hole Fully screw down the retaining screw 4 manually the screw must perfectly engage in the notch of the crankshaft ...

Page 107: ...e intake camshaft 2 and then the exhaust camshaft 1 with a suitable tool making sure not to damage the sealing surface Remove the timing chain 3 first from the intake camshaft sprocket and then from the exhaust shaft and fix it in a suitable point to prevent it from falling Remove the camshaft on the intake side 2 Remove the camshaft on the exhaust side 1 Half ball replacement Half balls can fall ...

Page 108: ...bricate all support surfaces with engine oil Pay attention to the position of the cam and fit the exhaust camshaft 1 with the EX mark on the relevant gear level with the sealing surface arrow Position the timing chain 2 on the exhaust camshaft gear Intake camshaft installation Lubricate all support surfaces with engine oil When screwing on the bearing mount the gears of the coolant pump and the cr...

Page 109: ...cate the mount 3 on the sliding surface with engine oil and fit it paying attention to the axial guides arrows Fit the sliding element support 4 Fit all the nuts 5 and tighten them fully by hand no tools Make sure that the mount 3 is positioned level on the side of the timing chain adjust the camshafts and the bearing bridge if necessary Fully tighten all the nuts according to the tightening seque...

Page 110: ...R 2012 2013 H10196 7 H10197 8 9 ENGINE SETTINGS AND ADJUSTMENTS Workshop Manual Ed 11 2011 Remove the locking screw 7 and re tighten the screw 8 to torque replac ing the gasket 9 Recheck valve clearance before refitting the head cover ...

Page 111: ...el to the sealing surface Check that the notch 3 arrow on the crank arm is visible through the hole marks EX and IN opposed and parallel to the surface and notch visible indicating correct timing If the notch 3 cannot be seen through the hole carefully turn the engine until it can be seen through the hole then fully tighten down the retaining screw 4 manually blocking the engine at TDC it must per...

Page 112: ...y described Chain tensioner disassembly Remove the screw A with the sealing ring B Remove the spring C and the chain tensioner D from the hole Loosen all the nuts 2 on the mount 1 Remove the slider 3 with the support 4 Remove the mount 1 Remove the sealing rings 5 Lift the camshaft 6 and 7 from the opposite side of the distribution gears to facilitate the removal of the chain then position the cam...

Page 113: ...tioned arrow Lubricate the mount sliding surfaces 3 with engine oil and fit it paying at tention to the axial guides arrows Fit the sliding element support 4 Fit all the nuts 5 and tighten them fully by hand no tools Make sure that the mount 3 is positioned level on the side of the timing chain adjust the camshafts and the bearing bridge if necessary Fully tighten all the nuts according to the tig...

Page 114: ... H10206 9 10 ENGINE SETTINGS AND ADJUSTMENTS Workshop Manual Ed 11 2011 Insert the chain tensioner replacing the gasket 9 and activate it manually to tension the timing chain checking that the timing is correct then tighten the screw 10 to torque ...

Page 115: ...F1 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 F1 Workshop Manual Ed 11 2011 GENERAL ENGINE PROCEDURES Section Refer to chapter F4 for all the engine tightening torques ...

Page 116: ...tallation F1 8 Tightening sequence of the right engine crankcase cover F1 8 FLYWHEEL AND STARTER MOTOR IDLE GEAR REMOVAL F1 9 Removal installation of the freewheel from on the flywheel F1 9 Freewheel control gear removal F1 9 Starter motor idle gear removal installation F1 10 Installation of the flywheel with freewheel control gear F1 10 CRANKSHAFT POSITION SENSOR REMOVAL INSTALLATION F1 11 CHAIN ...

Page 117: ...gaskets are preassembled Gearbox lever removal installation Removal Loosen the screw 1 then remove the lever 2 Installation Fit the lever 2 and tighten the screw to torque 1 Oil dipstick removal Remove the oil dipstick 1 Cover removal Remove the screws 1 Remove the gasket 2 and the cover 3 paying attention to the sealing ring and the gearbox shaft Pay attention to the thrust washer arrow it may st...

Page 118: ...ubricate the seal lip of the new oil seal then fit it on the cover using an appropriate tool Clutch disengagement shaft removal Remove the retaining ring 1 Extract the clutch disengagement shaft 2 Remove the spring 3 Clutch disengagement shaft oil seal removal Protect the housing from damage using adhesive tape arrow Lift the oil seal 1 using a suitable screwdriver Clutch disengagement shaft beari...

Page 119: ...en the bearing and the cover Remove the bearing Installation of both clutch disengagement shaft bearings Lightly lubricate both bearings with engine oil Install the needle roller bearings 1 and 2 Drive the upper needle roller bearing 2 until it is flush with the sealing ring housing using a suitable tool Disengagement shaft installation Lubricate the clutch disengagement shaft with engine oil Inse...

Page 120: ...les arrow The space washer 2 must engage on the gearbox shaft The main oil ducts 3 must not be dirty or obstructed Fit the cover 4 with the new gasket 6 on the engine housing paying atten tion to the calibrated pins 7 and the sealing ring 8 of the gearbox shaft Tighten the screws 5 manually Tightening sequence of the left engine crankcase cover The tightening sequence for the left engine crankcase...

Page 121: ...bber sheath from the cover and remove the stator 2 with the cable Stator assembly Clean the threading in the cover Insert the stator in the cover the cable support 1 must be in the slit arrow Precisely position the stator 2 using the holes of the screws Tighten the screws 1 to the tightening torque Insert the rubber sheath in the cover Fit the cable gland 3 and the screws 4 If the cover has been r...

Page 122: ...r installation Apply a layer of sealant Three Bond 1209 on the sealing surface of the rubber sheath 2 Clean the sealing surfaces Fit the new gasket 3 and the engine crankcase cover 2 Tighten the screws 1 Tightening sequence of the right engine crankcase cover The tightening sequence for the right engine crankcase cover goes from 1 to 14 The indicated tightening sequence must be followed ...

Page 123: ...heel hub 2 to a temperature of approx 100 C Remove the flywheel together with the freewheel 2 using a suitable puller Check the tab and replace it if necessary Removal installation of the freewheel from on the flywheel Removal Unscrew the screws 3 and remove the flange 4 and the freewheel 5 from the flywheel 2 Installation Check the condition of the freewheel 5 and replace it if it is ruined Refit...

Page 124: ... and lubricate with engine oil Fit the freewheel gear 1 into the crankshaft Clean the cone of the crankshaft and of the flywheel Apply a thin layer of Loctite 648 on the crankshaft cone Pay attention that the freewheel bearing does not come into contact with the Loctite Fit the flywheel 2 onto the crankshaft making sure that the groove and the key 6 are aligned and that the freewheel is set on the...

Page 125: ...2 and the tapered washer 3 Remove the sprocket 4 using a puller if necessary being careful not to ruin the shaft threading Installation Clean and lubricate the teeth on the main shaft and on the sprocket with KLUEBER 46 MR 401 grease Couple the sprocket 4 to the shaft being careful to keep the side with the thicker shoulder facing towards the engine Insert the tapered washer 3 so that the larger d...

Page 126: ... Remove the screws 1 Extract the starter motor paying attention to the sealing ring 2 Installation Check the sealing ring 2 for damage and replace it if necessary Clean and lubricate the ring 2 then place it on the starter motor Lubricate the centring tang 3 and the teeth 4 Fit the starter motor on the crankcase and fix it with the screws 1 tightening them to torque ...

Page 127: ...l seal 4 centring it on the shaft 5 then using a rubber ham mer and a suitable punch 6 insert it in the relevant seat until the external edge of the oil seal 4 is flush with the inside of the bevelled edge NOTE Make sure that the inner lip of the oil seal 4 is not damaged during installation due to the profile of the shaft Installation Check the sealing ring 3 replace it if ruined and fit it on th...

Page 128: ...ine at the top dead centre as described in the relevant paragraphs Loosen the screws 1 proceeding with diametrically opposite operations then remove them with the washers 2 and the springs 3 Lift the pressure plate 5 Remove the disengagement element 4 Remove the lined plates 6 and the steel plates 7 Insert the special tool A on the hub 10 to block rotation Remove the nut 8 with the corrugated wash...

Page 129: ...GINE PROCEDURES Disassemble the clutch housing 12 paying attention to the needle roller bearings 13 and the space bushing 14 Disassemble the control gear 15 and the thrust washer 16 Installation Fit the washer 16 Insert the oil pump control gear 15 in the clutch housing 12 being careful to correctly couple the engagements of the two parts ...

Page 130: ... primary shaft The clutch shaft oil nozzle shall not be dirtied with threadlocker Insert the special tool A on the hub 10 to block rotation Fit the corrugated washer 9 and the nut 8 and tighten to torque Remove the special tool A Lubricate the lined plates 6 with engine oil Insert first the steel plate 7 with the notch arrow with the sharp edge facing inwards then insert a lined plate 6 with narro...

Page 131: ... relevant paragraph Clutch pressure plate disassembly Disassemble the pressure plate 1 as described in the paragraph Clutch disassembly Position the pressure plate with the upper side facing downwards Heat the pressure plate to approx 80 C Remove the disengagement bearing 2 using a suitable puller Clean the housing of the support Lubricate the clutch disengagement bearing with engine oil Heat the ...

Page 132: ...e condition of the pin 3 and replace it if necessary Installation Clean all components prior to installation and lubricate them with engine oil Insert the pin 3 in the shaft Place the rotating piston 1 on the shaft with the mark 4 facing outwards paying attention to the correct positioning of the pin 3 Fit the rotor 2 with the mark 5 facing outwards so that it coincides with the mark 4 on the rota...

Page 133: ...allation Remove the complete clutch as described in the relevant paragraph Removal Disassemble the retaining ring 4 and the washer 3 Disassemble the gear 2 Disassemble the drive pin 1 Remove the screws 5 Remove the cover 6 Disassemble the rotating piston 7 and the rotor 8 extract the pin 9 from the shaft Check the condition of the pin 9 and replace it if necessary ...

Page 134: ...lean the sealing surfaces Fit the cover 6 paying attention to the centring pin 12 Tighten the screws 5 to torque Check the drive pin 1 for wear and replace it if it is ruined Insert the drive pin 1 in the shaft Fit the gear 2 making sure it engages on the drive pin Fit the washer 3 Fit the new retaining ring 4 Refit the clutch as described in the relevant paragraph Oil pump shaft disassembly Remov...

Page 135: ...levant paragraph Open the pipe clamps 1 using a suitable tool and disconnect the pipes 2 from the radiator 3 and from the pump cover 4 Open the pipe clamps 5 using a suitable tool and disconnect the pipes 6 Unscrew the screws 7 paying attention to the washer 8 Remove the pump cover 4 with the gasket 9 Use a suitable tool to disassemble the impeller 10 right hand threading Unscrew the screw 11 Remo...

Page 136: ...ean it if necessary Clean the seat of the pump in the engine cylinder head Lubricate the washers 15 the bearing 16 and the pin 17 with engine oil Lubricate the pump shaft through the hole 18 with engine oil Make sure the control gear 13 is correctly positioned on the shaft The pin 17 must engage in the control gear 13 Seal the pump support surface 19 using Three Bond 1209 sealant Lubricate the sea...

Page 137: ... Insert the pump body 12 with the driving wheel in the engine head making sure the teeth engage with the gear of the camshaft Push the pump 12 all the way down with a suitable pipe bushing applying pressure only on the outer edge of the pump Tighten the screw 11 to torque Fit the impeller 1 screwing it onto the pump shaft Replace the gasket 9 and insert it in the water pump cover 4 Fix the cooling...

Page 138: ...l gear removal installation Removal Remove the coolant pump Remove the head cover fix the engine at the top dead centre remove the chain tensioner and remove the camshaft bearing mount as described in the relevant paragraphs First lift the intake camshaft 2 and then the exhaust camshaft 1 with a suitable tool making sure not to damage the sealing surface Remove the timing chain 3 first from the in...

Page 139: ...ibed in the relevant paragraph Installation Clean the threading and the washer 5 Clean the contact surface and fit the driving wheel 7 Tighten the screw 4 left hand threading and the washer 5 to torque blocking the shaft from the socket 6 Reassembly Refit the coolant pump and the camshafts as described in the relevant para graphs Refit the other components previously removed as described in the re...

Page 140: ...cribed in the relevant paragraph Removal Release the oil manifold prongs 3 from the retainers 4 Remove the manifold 3 the gasket 2 and the mesh filter 1 Clean or replace the mesh filter 1 Installation Check the oil manifold gasket 2 and replace it if necessary The manifold must be precisely inserted in the cover of the swing arm hous ing as any leaks cause a reduction in oil delivery Check the pro...

Page 141: ...t 2 Remove the screws 3 Remove the cover 4 Remove the gasket 5 Installation Clean the threading and the sealing surfaces The pin of the compensation connecting rod axis could detach During installation make sure that the pin of the compensation connecting rod axis is correctly fixed in its seat Check the correct positioning of the pin 6 Fit the gasket 5 and the cover 4 on the crankcase Manually ti...

Page 142: ... cover as described in the relevant paragraph Disassemble the oil pressure valve 1 with the spring 2 Check the condition of the valve Insert the valve in the cover and activate it a few times to check spring elas ticity If the valve does not function properly it must be replaced Check that the seat of the oil delivery valve is not dirty and clean it if neces sary Clean the valve seat Installation ...

Page 143: ...n Remove the camshaft bearing mount Remove the chain tensioner Remove both camshafts Remove the timing chain slider Remove the chain sprocket Remove the oil sump Remove the swing arm housing cover Remove the right engine crankcase cover Release the fastening at the top dead centre Remove the gearbox lever Remove the left engine crankcase cover Remove the selector shaft Remove the lower part of the...

Page 144: ...emove it Remove the screw 5 Extract the chain tensioner slider 6 towards the bottom Replace the chain tensioner slider refitting it in the opposite direction tight ening the screw 5 to torque Installation Insert the timing chain 4 in the relevant recess and place it on the crankshaft sprocket Before lowering the crankshaft 3 lubricate all supporting points with engine oil Carefully remove the supp...

Page 145: ...ews 1 to torque referring to the installation sequence from 1 to 8 Refit the previously removed parts as described in the relevant paragraphs HEAT EXCHANGER REMOVAL INSTALLATION Removal During the installation removal operations make sure not to mix liquids from different circuits Drain the coolant and the oil as described in the relevant paragraphs Remove the screws 1 Refit the heat exchanger 2 R...

Page 146: ......

Page 147: ...F2 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 Workshop Manual Ed 11 2011 CYLINDER HEAD REMOVAL DISASSEMBLY F2 Section Refer to chapter F4 for all engine tightening torques ...

Page 148: ... Chain tensioner removal installation F2 4 Locking the crankshaft F2 5 Crankshaft locking screw removal F2 5 Camshaft mount disassembly F2 6 Camshaft mount assembly F2 6 Camshaft removal replacement F2 8 Timing chain slider replacement F2 10 Rocker arm removal installation or replacement F2 11 Cylinder head removal installation replacement of cylinder head gasket F2 12 Cylinder head disassembly F2...

Page 149: ...SASSEMBLY Removal of the ignition coil from the spark plug recess Remove the ignition coil from the spark plug recess 1 Cylinder head cover removal installation Removal Remove the screws 1 Remove the head cover 2 with the gaskets 3 and 4 Installation Apply Three Bond 1209 sealant on the new gasket in the indicated point arrows ...

Page 150: ...ce the sealing ring 5 Position the head cover 2 paying attention to the breather opening arrow The opening arrow rests on the sealing ring 5 Tighten the screws 4 to torque in a diametrically opposite order Chain tensioner removal installation Removal Remove the screw 1 with the sealing ring 2 Remove the spring 3 and the chain tensioner 4 from the hole Installation Insert the chain tensioner 4 and ...

Page 151: ...rks IN and EX on the camshaft gears are facing each other and are level with the seal ing surface Remove the screw 1 with the sealing ring 2 Check if the notch 3 arrow on the crank arm is visible through the hole Manually tighten the retaining screw 4 fully down it must perfectly engage in the notch of the crankshaft Crankshaft locking screw removal Remove the screw 4 and tighten the screw 1 to to...

Page 152: ... and fit them Before fixing the mount make sure that the axial camshaft guide is correctly positioned arrow Lubricate the mount 3 on the sliding surface with engine oil and fit it paying attention to the axial guides arrows Fit the sliding element support 4 Fit all the nuts 5 and tighten them fully by hand no tools Make sure that the mount 3 is positioned level on the side of the timing chain adju...

Page 153: ...10196 7 H10197 8 9 Workshop Manual Ed 11 2011 CYLINDER HEAD REMOVAL DISASSEMBLY Remove the crankshaft locking screw 7 and re tighten the screw 8 to torque see chapter F4 replacing the gasket 9 Recheck valve clearance before refitting the head cover ...

Page 154: ...he timing chain 3 first from the intake camshaft sprocket and then from the exhaust shaft and fix it in a suitable point to prevent it from falling Remove the camshaft on the intake side 2 Remove the camshaft on the exhaust side 1 If the camshafts must be replaced proceed as follows Remove the screw 4 locking the camshaft 2 and 3 by means of the socket Remove the chain gear 5 Remove the water pump...

Page 155: ...cate all support surfaces with engine oil Insert the intake side camshaft 2 place the timing chain 3 on the inner side of the gear Fit the timing chain 3 on the exhaust side camshaft 1 paying attention to the EX mark The EX mark must be level with the sealing surface Fit the timing chain 3 on the intake side camshaft 2 paying attention to the IN mark The IN mark must be level with the sealing surf...

Page 156: ...escribed in the relevant paragraphs Unscrew the screw 1 Remove the mobile chain tensioner slider 2 towards the top Remove the fixed slider 3 of the timing chain towards the top Check the chain sliders for wear and replace them if worn Insert the slider 2 Clean the threading Tighten the screw 1 to torque with Loctite 243 Insert the slider 3 Refit the camshafts the chain tensioner and the clutch cov...

Page 157: ...ucts Plug ducts with a cloth Overturn the rocker arms 1 upward and remove the half balls 2 using a magnet Return the half balls 2 to their seats in an orderly manner Remove the safety clips 3 Extract the rocker arms 1 from the pins 4 Installation Lubricate the pins 4 of the rocker arms 1 with engine oil Replace the safety clips 3 Fit the rocker arms 1 on the pins 4 then fit the safety clips 3 The ...

Page 158: ...emove the cylinder head 3 release the gasket to be replaced 4 tapping it lightly if needed Installation Clean cylinder head and engine crankcase sealing surfaces and fit a new gasket 4 Fit the head 3 paying attention to the head crankcase coupling by means of the centring pins 5 Tighten the screws 1 and 2 manually Tighten the screws 2 according to the indicated order and according to what is speci...

Page 159: ...ve the cylinder head as described in the relevant paragraph Remove the cooling pump as described in the relevant paragraph Remove the rocker arms as described in the relevant paragraph Disassembly Loosen the clamps 1 and remove the intake coupling 2 Remove the temperature sensor 3 Remove the rocker arm pins 4 Valve removal Place a suitable protection to the side under the cylinder head so that the...

Page 160: ...ts using a suitable tool Installation Lubricate the valve stems with engine oil and insert the valves 9 in the head Insert the gasket 10 on the valve stem being careful not to ruin the sealing lip Using a suitable tool push the gasket 10 in its seat in the cylinder head Repeat the operation also for the other three valves Fit the lower valve spring retainer 8 Fit the valve spring 5 and the upper v...

Page 161: ...al Ed 11 2011 CYLINDER HEAD REMOVAL DISASSEMBLY Fit the intake couplings 2 and fix them with the clamps 1 being careful to position their hooks downwards Fit the temperature sensor 3 Refit the rocker arms the cooling pump and the head as described in the relevant paragraphs ...

Page 162: ......

Page 163: ...F3 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 F3 Workshop Manual Ed 11 2011 CRANKCASE DISASSEMBLY Section Refer to chapter F4 for all engine tightening torques ...

Page 164: ... ring removal F3 13 Piston ring assembly F3 13 Piston installation F3 14 Installing the pistons with the connecting rod F3 14 Chain tensioning slider installation F3 15 Main split bearing installation F3 15 Crankshaft installation F3 15 Main bearing cap installation F3 16 Connecting rod cap installation F3 16 Compensation arm installation F3 17 Gear selector drum installation F3 18 Installation of...

Page 165: ...filter Remove the oil sump Remove the floating arm casing Remove the clutch cover Remove the complete clutch Remove the ignition cover Remove the complete ignition Remove the complete oil pump intake delivery Remove the gearbox potentiometer Remove the sprocket Remove the crankshaft sensor Refer to the relevant paragraphs chapters for the removal operations Fit the engine on a suitable support in ...

Page 166: ...s Remove the safety pin 3 Using a suitable puller remove the pin 4 of the compensation arm 5 Rotate the compensation arm 5 upward Remove the screws 6 Remove the lower crankcase half 7 towards the top making sure the split bearings do not fall out Slightly lift the gearbox output shaft 8 and remove the oil seal 9 Gearbox removal Remove the gearbox output shaft 8 and input shaft 9 ...

Page 167: ...roller bearing 5 Extract the washer 6 Extract the idle wheel 7 Remove the retaining ring 8 Extract the idle wheel 9 and 10 During the removal operations be careful not to ruin the needle roller bearings Remove the needle roller bearings 11 and 12 being careful not to damage the rollers Remove the retaining ring 13 Extract the idle wheel 14 Remove the retaining ring 15 Extract the idle wheel 16 Rem...

Page 168: ...le wheel 14 with the groove facing outwards Fit a new retaining ring 13 in its seat Clean the supporting points and lubricate them with engine oil Fit the needle roller bearings 11 and 12 being careful not to damage the rollers Fit the idle wheel 10 with the engagement gear gripping grooves facing forward Fit the idle wheel 9 with the engagement gear gripping grooves facing outwards Fit a new reta...

Page 169: ...ay become significantly worse Replace the paired gears but one at a time All components must be checked before being installed If imperfections are found replace them Clean the supporting points and lubricate them with engine oil Insert the idle wheel 10 the toothed engagements must face the sliding seat Insert the ring 9 Fit a new retaining ring 8 in its seat Clean the sliding seat and lubricate ...

Page 170: ... drum star removal Remove the shift drum star as follows Plug the openings in the crankcase with rags Turn the star 3 one notch from the neutral position arrow Unscrew the screw 2 Move the ratchet 1 and remove the star 3 Ratchet removal Remove the ratchet 2 by unscrewing the screw 1 and removing the bush ing 3 and the spring 4 Gearbox fork removal Remove the safety pin 1 Remove the fork pin 2 Remo...

Page 171: ... Gear selection drum removal Remove the screw 1 Remove the drum 2 from the lower crankcase half Gear selection drum disassembly Removal Fit the original screw 1 to protect the threading in the selector drum Remove the external bearing of the selector drum 2 using a suitable puller Heat the drum in the area of the internal bearing to approx 80 C Rotate the drum 3 to let the internal bearing 4 fall ...

Page 172: ...pprox 80 C Fit the external bearing 1 on the drum making sure that the bearing rests correctly on the relevant drum seat CRANKSHAFT REMOVAL Compensation arm removal Move the compensation arm backwards and remove the screws 1 Remove the connecting rod caps 2 and the balancing connecting rod 4 The connecting rod and the compensation arm must not be disas sembled Remove the split bearings 3 Connectin...

Page 173: ...ings 3 from the two caps 2 Mark the exhaust side on the pistons Extractbothconnectingrods 4 withthepistons 5 downwards beingcareful not to damage the cylinder liners the crank pins or the split bearings 6 Main bearing cap removal Mark the installation position of the two caps before removing them The caps must not be inverted Remove the screws 1 and the two caps 2 Crankshaft removal Release the ti...

Page 174: ...l Tighten the connecting rod 1 in the vice with the protective jaws Remove the retaining rings 2 Remove the piston pins 3 Check the wear of the piston pins and replace them if scored or ruined Visually check the wear of the piston 4 in particular if there are traces of wear and grooves Using a bracket gauge measure the diameter of the piston at a right angle in the direction of the piston pin Pist...

Page 175: ...e an equal length of wire on both sides do not shorten it Fit the torsion spring 2 with metal wire 3 Fit the support ring 4 at the bottom using the pliers for piston rings in the 3rd groove of the piston Fit the support ring 1 at the top using the pliers for piston rings in the 1st groove of the piston Form of piston segment 3rd Scraper ring type Form of piston segment 2nd groove Tapered type with...

Page 176: ...ed on the piston pin Fit the new safety rings 1 Hook the safety ring with the prong in the notch and press them in the groove the ring must engage correctly in the specific seat Installing the pistons with the connecting rod Turn the engine to the installation position Pay attention that the gaps between the sealing rings do not coincide with the piston rotation axis Turn both the piston ring gaps...

Page 177: ...em if necessary Clean the split bearings and the relevant seats The lubrication holes of the split bearings must be located above the oil channels Fit all the split bearings in pairs inserting the prongs in the respective seats If the crankshaft is replaced also replace the main split bearings Crankshaft installation Clean the sealing surfaces Before fitting the crankshaft 2 lubricate all supporti...

Page 178: ...dicated sequence from 1 to 8 then perform the final tightening as specified in the relevant chapter The screws must be replaced at each reassembly Connecting rod cap installation Clean and lubricate the contact surfaces of the connecting rod and the con necting rod caps Lubricate the sliding surfaces with engine oil Fit the caps 2 on the connecting rods paying attention to the marks ar rows Replac...

Page 179: ... in the compensation arm Clean and lubricate all the connecting rod separation surfaces Lubricate the sliding surfaces with engine oil fit the connecting rod caps 2 and the balancing connecting rod 3 paying attention to the mark arrow The marks face forward in the direction of travel Replace the screws 1 Orient the compensation arm The screws must be replaced at each reassembly Tighten the screws ...

Page 180: ...ition Fit the engagement fork 2 on the selector drum Fully insert the pin 1 from the crankcase side and in the fork 2 Check that the fork was correctly inserted in the drum and that it moves freely Installation of the 1st 3rd and 2nd 4th gear engagement fork Check the wear of the forks 3 and the pin 2 replace them if worn or ruined Clean all components and lubricate them with engine oil Fit the en...

Page 181: ...pin 4 in the hole 5 of the drum Tighten the screw 2 to torque Reassembly of the gearbox input and output shaft Clean all the supporting points and lubricate them with engine oil Fit the shafts 1 and 2 Turn the bearing of the gearbox output shaft and the relevant fixing rings to the installation position The pin arrow must be in the notch of the engine crankcase half Position the notch of the beari...

Page 182: ...nt Clean the sealing surfaces ApplyalayerofLoctite5910sealant orDowCorning inthezonerepresented on the lower part of the crankcase Apply a layer of sealant in the sector 1 on the external edge because in this sector the throttle 2 and the oil pipe 3 are located in the upper part of the engine crankcase half Before fitting the lower part of the engine crankcase half make sure that the star coupling...

Page 183: ...oil When inserting the lower part of the engine crankcase half pay attention to the centring pins Check the correct position of the gearbox bearing The pin arrow must be in the notch of the engine crankcase half Position the notch arrow of the bearing fixing ring upward Orient the compensation arm upwards and place the lower part of the engine crankcase half 1 on the upper one Manually tighten the...

Page 184: ...sition and fully screw down the screws manually paying attention to their length Fixing the crankcase halves Rotate the engine upwards with the lower part of the relevant crankcase Tighten the screws from 1 to 4 according to the indicated sequence and according to what is specified in the relevant chapter Tighten the screws to torque in the installation sequence from 5 to 9 The screws 1 to 4 must ...

Page 185: ... the installation sequence from 12 to 23 Gearbox output shaft oil seal installation Fill the new oil seal between the inner sealing lips with grease Clean the crankcase Fit the oil seal 1 on the outer side using a specific pad being careful to protect the inner lip from the scoring on the shaft Refit all the previously removed components as described in the relevant para graphs ...

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Page 187: ...specified torque using a torque wrench An insufficiently tightened screw or nut could get damaged or come completely loose damaging the motorcycle and or injuring the rider A screw or nut tightened beyond the permitted max torque value might get damaged or break and therefore come completely loose The specified values refer to clean threads ...

Page 188: ...F4 2 NUDA 900 2012 2013 NUDA 900 R 2012 2013 ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 KEY A Lubricate with engine oil B Grease C Tighten manually CONVERSION TABLE 1 Nm 0 1 Kgm 1 Nm 0 73756 ft lb ...

Page 189: ...13 H10454 12 Nm 30 Nm 12 Nm Loctite 648 Loctite 5910 Loctite 648 25 Nm 12 Nm 1 15 Nm 2 80 5 12 Nm 1 15 Nm 2 45 5 19 Nm 19 Nm 12 Nm 10 Nm Klueber 46 MR A A A Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES Replace the screws at each reassembly ...

Page 190: ...F4 4 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10455 12 Nm Loctite 243 40 Nm 12 Nm Loctite 243 14 Nm 12 Nm 12 Nm 10 Nm 30 Nm A 12 Nm 1 5 Nm 2 20 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 ...

Page 191: ...5 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10456 1 10 Nm 2 30 Nm 3 135 1 5 Nm 2 20 Nm 3 95 A A A A 1 5 Nm 2 20 Nm 3 95 Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES Replace the screws at each reassembly ...

Page 192: ... 900 2012 2013 NUDA 900 R 2012 2013 H10457 10 Nm 17 mm 1 mm 30 5 mm 1 mm 20 Nm 19 Nm 10 Nm 1 30 Nm 2 270 ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 Replace the screws and the head gasket at each reassembly ...

Page 193: ...F4 7 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10458 10 Nm Loctite 243 40 Nm 10 Nm 50 Nm Loctite 243 Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES ...

Page 194: ...F4 8 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10459 Three Bond 1209 10 Nm 10 Nm Loctite 243 ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 ...

Page 195: ...013 NUDA 900 R 2012 2013 H10460 30 Nm 12 Nm 12 Nm 10 Nm Three Bond 1209 Klueber 46 MR 401 Loctite 243 C 5 Nm A A H10461 50 Nm Loctite 243 Klueber 46 MR 401 Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES Left hand thread ...

Page 196: ...F4 10 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10462 B 5 Nm Loctite 243 10 Nm Loctite 243 10 Nm 10 Nm Loctite 243 ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 ...

Page 197: ...F4 11 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10463 180 Nm Loctite 648 10 Nm Klueber 46 MR 401 Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES ...

Page 198: ...F4 12 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10464 12 Nm C ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 ...

Page 199: ... 900 R 2012 2013 H12017 10 Nm B Three Bond 1209 4 Nm Loctite 243 10 Nm 11 Nm 12 Klueber 46 MR 401 Klueber 46 MR 401 Loctite 648 35 Nm Loctite 648 140 Nm Loctite 648 10 Nm Loctite 243 Workshop Manual Ed 11 2011 ENGINE TORQUE FIGURES ...

Page 200: ...F4 14 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10466 12 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 11 2011 ...

Page 201: ...F5 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 F5 WEAR LIMITS OF ENGINE PARTS Workshop Manual Ed 11 2011 Section ...

Page 202: ...e wear value table F5 3 Crankshaft Casing assy F5 3 Connecting rod F5 3 Compensation connecting rod compensation arm F5 3 Gearbox F5 4 Gear shift control F5 5 Clutch F5 6 Piston F5 6 Piston pin F5 7 Cylinders Casing assy F5 7 Timing chain F5 7 Head F5 7 Valves F5 8 Oil pump F5 9 Starting device F5 9 Spark plug F5 9 ...

Page 203: ...d Connecting rod stem assy 45x48x15 bush ing Measurement in the di rection of travel Ø 45 01 45 03 mm max Ø 45 05 mm Small traces of cavitation are permitted Big end radial clearance Crankshaft assy Con necting rod stem assy 45x48x15 bushing In the direction of travel 0 026 0 062 mm max 0 08 mm Connecting rod stem Ø small end Connecting rod stem assy In the direction of travel Ø 18 0 02 0 01 mm ma...

Page 204: ...for bear ing pin Casing assy Measured horizontally direction of travel Ø 16 0 016 0 034 mm max Ø 16 06 mm Gearbox Bore in the casing for deep groove ball bear ings of the gear shafts Casing assy Magnet side main shaft Clutch side main shaft Magnet side output shaft Clutch side output shaft Ø 72 0 045 0 065 mm Ø 52 0 045 0 065 mm Ø 47 0 045 0 065 mm Ø 62 0 055 0 065 mm Perform a visual check Main s...

Page 205: ...rZ24 Version with sliding bearings Ø 29 0 08 0 10 mm max Ø 29 15 mm Gearbox gears Groove width for control fork Gearbox gear Z24 Gear box gear Z25 Gearbox gear Z21 23 6 1 0 0 1 mm max 6 25 mm Gear shift control Thickness of the gear en gagement fork plates Engagement fork 1st 3rd gear Engagement fork 2nd 4th gear Engagement fork 5th 6th gear 5 9 0 0 075 mm min 5 60 mm Axial clearance of the engage...

Page 206: ...presence of notches in the guide grooves of the clutch housing and in the outer toothing of the driver Clutch housing assy Driver 0 mm max 0 3 mm Piston Ø piston Piston assy 83 97 mm with graphite layer Measured 4 mm from the lower edge of the piston transversally to the piston pin axis Ø 83 966 0 012 mm min Ø 83 94 Piston installation clear ance Piston assy 83 97 mm Casing assy 0 015 0 053 mm max...

Page 207: ...he chain ten sioner slider and in the chain guide Chain tensioner pad Chain guide Upper chain guide 0 mm max 0 8 mm Head Diameter of chain ten sioner holes Cylinder head assy Ø 14 0 006 0 024 max Ø 14 05 mm Permitted deformation of the sealing surface Cylinder head assy On the entire surface max 0 03 mm max 0 04 mm Intake cam height Intake camshaft 39 97 0 1 mm min 39 85 mm Exhaust cam height Exha...

Page 208: ...ke valve 31 33mm Exhaust valve 27 5 28 5 mm Check with a ruler the support surface must not be concave Intake valve Ø valve stem Intake valve 31 33 mm Ø 4 973 0 007 mm min Ø 4 950mm Exhaust valve Ø valve stem E x h a u s t v a l v e 27 5 28 5mm Ø 4 963 0 007 mm min Ø 4 940mm Valve guide Wear limit Ø bore Cylinder head assy Measured with gauge Ø 5 H7 0 0 012 max Ø 5 04 mm Intake valve Valve stem ra...

Page 209: ...sy Delivery pump Cover 0 02 0 09 mm max 0 15 mm Grooves are permitted on the cover and in the casing Axial clearance between oil intake pump and cas ing Casing assy Intake pump Cover 0 02 0 14 mm max 0 18 mm Grooves are permitted on the cover and in the casing Oil pressure Insert the oil pressure gauge in the head in the place of the M12x1 5 screw plug Measurement at an oil temperature of 80 C 1 5...

Page 210: ......

Page 211: ...I 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 I Workshop Manual Ed 11 2011 FRONT SUSPENSION Section ...

Page 212: ...SUSPENSION Workshop Manual Ed 11 2011 Sommario Front end I 3 Disassembly I 4 Assembly I 6 Suspension settings summary tables I 8 Servicing forks I 10 Bushings and seals replacement I 13 Assembly I 14 Servicing of the damper I 15 Damper reassembly I 17 ...

Page 213: ...NUDA 900 R 2012 2013 H10576 1 2 2 2 3 4 5 6 6 7 7 8 Workshop Manual Ed 11 2011 FRONT SUSPENSION Front end Key 1 Steering nut 2 Fork leg retaining screws 3 Steering head 4 Ring nut 5 Bottom yoke 6 Bearings 7 Dust seal 8 Washer ...

Page 214: ... the wheel the headlight the front mudguard as described in the rel evant paragraphs Loosen the four screws 1 and move the handlebar without removing it Protect carefully the fairings and the painted parts to prevent scratches and or damages Loosen the nut 2 of the steering tube Loosen the screws 3 from both sides and remove the fork leg stems 4 ...

Page 215: ...anual Ed 11 2011 FRONT SUSPENSION Fully loosen the nut 2 and remove the steering head 5 Loosen the ring nut 6 and remove the bottom yoke 7 with the related bearings 8 and the dust seal 9 In case of replacement of the bearings remove the seats 10 by hitting alternatively on the seat with an aluminium punch ...

Page 216: ...th grease before reassembling them Install the bottom yoke 1 the upper bearing 2 and the dust seal 3 the tighten the ring nut 4 to the pre tightening torque so that the bearings settle on the respective seats pre tightening torque is around half the value of the tightening torque Loosen the ring nut 4 and tighten it to the specified tightening torque Install the steering head 5 and tighten manuall...

Page 217: ...pending on the type of use as described in the following table lock them in position by tightening the lower screws 8 to torque For the Nuda 900R version it is possible to adjust the suspension according to the type of use of the motorcycle and its load It is also possible to adjust the motorcycle suspension for use on the track Motard version ...

Page 218: ...ks 14 clicks 16 clicks Rebound adjustment shock absorber 25 clicks 10 clicks 18 clicks 9 clicks 18 clicks Constant K spring shock absorber 105 N mm 105 N mm 100 N mm 100 N mm 100 N mm FORK NUDA 900 NUDA 900 with panniers and pas senger NUDA 900 R NUDA 900 R Motard NUDA 900 R with panniers and pas senger Compression adjustment 6 clicks 3 clicks 6 clicks Rebound adjustment 10 clicks 10 clicks 10 cli...

Page 219: ...00 R 2012 2013 H10631 6 H10660 9 Workshop Manual Ed 11 2011 FRONT SUSPENSION Tighten the nut 6 to torque Tighten the upper screws 9 of the fork leg stems to torque Reassembleinreverseordertheothercomponentsthatwerepreviouslyremoved ...

Page 220: ...nly for NUDA 900 R Before starting the fork servicing procedures make note of its set ting compression rebound pre load then position the adjuster screws on the maximum opening Loosen the cap 1 from the fork sleeve 2 Lower the fork sleeve 2 to gain access to the damper 3 Slightly squeeze the spring 4 and insert the key in the nut 5 on the damper rod 7 ...

Page 221: ...0592 6 H10593 2 7 Workshop Manual Ed 11 2011 FRONT SUSPENSION Loosen the cap 1 from the rod Remove the spring 4 Remove the adjuster rod 6 inside the damper rod 7 Turn the fork sleeve 2 upside down so the oil can come out Move the rod 7 so the oil can come out easily ...

Page 222: ... 11 2011 Lock the foot 8 with a vice with aluminium jaws Insert the proper tool in the fork leg to lock the bushing of the damper Fit the tool in the respective seats of the damper so that it does not turn while you loosen the valve assembly Loosen the bottom valve assembly 9 NOTE Be careful if the oil comes out ...

Page 223: ...Workshop Manual Ed 11 2011 FRONT SUSPENSION Remove the bottom valve assembly 9 Remove the damper 10 from the fork sleeve Bushings and seals replacement Use a screwdriver to remove the dust seal 11 making sure not to damage it Use a flat head screwdriver to remove the retaining ring 12 ...

Page 224: ...te Remove the bushings and the sealing rings from the fork leg Check the bushings for wear and tear If they show wear replace them Assembly Insert again the dust seal 11 with a suitable tool to prevent the cutting of the sealing ring lip Ensure the correct direction of assembly Insert again the sealing ring 14 with a suitable tool to prevent the cutting of the lip Ensure the correct direction of a...

Page 225: ...he sealing ring 14 until it is fully inserted in the seat Make sure that you do not deform it and ensure that it is fully inserted Reassemble the ring 12 that retains the sealing ring 14 in the seat ensur ing that it is correctly positioned in the seat then install the dust seal 11 Servicing of the damper Tighten the damper 10 with a vice by using two shaped shells and ensure that the damper is no...

Page 226: ...10613 16 FRONT SUSPENSION Workshop Manual Ed 11 2011 Heat the area of the bushing 15 in order to remove the Loctite Loosen the bushing 15 with a suitable tool Remove the bushing 15 with the damper rod Check the piston reeds assembly 16 and if needed replace the defective parts ...

Page 227: ...rkshop Manual Ed 11 2011 FRONT SUSPENSION Damper reassembly Insert again the rod assembly 7 in the damper 10 Tighten the bushing 15 with Loctite 243 using a suitable tool Insert again the damper assembly 10 in the fork leg 13 Reassemble the bottom valve 9 applying Loctite 242 on the thread ...

Page 228: ...e bottom valve to torque 50 Nm 5 Kgm 36 88 ft lb Insert again the adjustment rod 6 Pour the oil in the fork sleeve 2 598 cc for NUDA 900 585 cc for NUDA 900 R After filling the cartridge check the oil level From the edge of the fork sleeve with leg fully butted up it must be 110 mm 4 33 in for NUDA 900 125 mm 4 92 in for NUDA 900 R ...

Page 229: ...624 1 H10625 1 Workshop Manual Ed 11 2011 FRONT SUSPENSION Possibly use a syringe to correct the level Insert a spring 4 and possibly a pre load tube Tighten the cap 1 on the rod 20 Nm 2 0 Kgm 14 75 ft lb Tighten the cap 1 on the fork sleeve 20 Nm 2 Kgm 14 75 ft lb ...

Page 230: ...20 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10626 FRONT SUSPENSION Workshop Manual Ed 11 2011 NOTE only for NUDA 900 R At the end restore the adjustments that were recorded before the servicing procedures ...

Page 231: ...J 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 J Workshop Manual Ed 11 2011 REAR SUSPENSION Section ...

Page 232: ...anual Ed 11 2011 Sommario Rear suspension J 3 Rear shock absorber removal J 3 Rear shock absorber spring replacement J 4 Mudguard chain guard removal J 6 Sprocket casing removal J 7 Rear swinging arm removal J 8 Chain upper slide removal J 9 Chain lower slide removal J 10 ...

Page 233: ...itions With regard to the hydraulic adjustments refer to the chapter Settings and Adjustments Periodically check all components for wear Rear shock absorber removal Remove the fuel tank as described in the relevant paragraph Position a suitable support under the engine and make sure that the motor cycle does not move Loosen the nut 1 and remove the pin 2 Loosen the upper pin 3 and remove it Remove...

Page 234: ...kshop Manual Ed 11 2011 Rear shock absorber spring replacement Put soft jaws on the vice and lock the shock absorber Fully loosen until the end stroke the lock ring nut 1 and the ring nut 2 in order to discharge the spring 3 Compress the spring remove the spring retainer 4 and remove the spring 3 ...

Page 235: ...1 REAR SUSPENSION Check the ring nuts 1 and 2 and the washer 5 for wear if they show wear or they are damaged replace them Install the new spring tighten the ring nut 2 and restore the correct length pre load as the drawing A shows Drawing A B spring in seat 162 5 15 mm 6 4 0 59 in C spring in seat 181 mm 7 13 in ...

Page 236: ... 2013 H10644 2 1 H10645 2 H10926 1 REAR SUSPENSION Workshop Manual Ed 11 2011 Tighten the lock ring nut 1 to torque Mudguard chain guard removal Loosen the screws 1 and remove the mudguard chain guard 2 slipping it off towards the rear side ...

Page 237: ...ke sure that the bushings are correctly positioned and that the rear brake hose 3 and the speed sensor wire 4 are correctly inserted in their respective seats Sprocket casing removal Loosen the two screws 1 and the screw 2 then remove the cover 3 NOTE During reassembly do not invert the screws but install them again exactly in the original position ...

Page 238: ...ke so that it does not move Remove the wheel and the chain mudguard as described in the relevant paragraphs Loosen the nut 1 and remove the pin 2 by slightly lifting the swinging arm Detach the support 3 with the calliper from the swinging arm 4 and remove the clamp 5 by loosening the related screw Loosen the nut 6 on the left side keeping the pin 7 steady on the right side then remove the pin 7 a...

Page 239: ...sition a suitable support under the engine and fasten the bike so that it does not move Remove the wheel and the sprocket casing as described in the relevant paragraphs Loosen the screw 1 and remove the sprocket 2 Loosen the upper screw 3 and the lower screw 4 keeping the valve spring retainers Remove the slider 5 toward the front side of the bike and replace it ...

Page 240: ...J 10 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10656 1 H10657 2 H10658 2 REAR SUSPENSION Workshop Manual Ed 11 2011 Chain lower slide removal Loosen the screw 1 turn the slider 2 and remove it downwards ...

Page 241: ...L 1 NUDA 900 2012 NUDA 900 R 2012 L Workshop Manual Ed 11 2011 BRAKES Section NON ABS version MY12 only ...

Page 242: ...ar braking system removal L 6 Front braking system removal L 8 Checking brake pads for wear replacing the pads L 10 Brake fluid replacement L 13 Fluid replacement and system bleeding L 13 Front braking system L 13 Rear braking system L 14 Bleeding the front braking system L 15 Bleeding the rear braking system L 17 ...

Page 243: ...m uses two independent circuits Each circuit is equipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front master cylinder 3 Front oil reservoir 4 Front line 5 Right hand front brake calliper 6 Left hand front brake calliper 7 Right hand front brake disc 8 Right hand front brake disc ...

Page 244: ...2 NUDA 900 R 2012 H10850 9 10 13 14 H10851 12 11 BRAKES Workshop Manual Ed 11 2011 9 Rear brake fluid reservoir 10 Rear line 11 Rear brake calliper 12 Rear brake disc 13 Rear master cylinder 14 Rear brake control pedal ...

Page 245: ... thickness wear limit mm 4 0 157 in Rear brake disc diameter mm 265 10 43 in Rear brake disc thickness when new mm 5 0 2 in Minimum disc thickness wear limit mm 4 5 0 177 in Thedistortionofthediscsmustnotexceed0 15mm 0 006in themeasurement should be made with a feeler gauge and a disc installed on the rim To remove the disc from the wheel rim you need to loosen the five retaining screws Onassembly...

Page 246: ...Manual Ed 11 2011 Rear braking system removal Remove the rear wheel 1 and the chain mudguard casing 2 as described in the relevant paragraph Unhook the spring 3 loosen the three screws 4 and remove the cover 5 so the master cylinder is free Loosen the screw 6 and remove the oil reservoir 7 ...

Page 247: ...se you need to replace the master cylinder 14 open the clamp 15 and detach the pipe 16 collecting the oil that comes out of the reservoir then loosen the coupling 17 and remove the delivery pipe 18 During the reassembly position the pipe 13 of the rear brake exactly in the original position and fasten it with the relevant clamps and cable ring Lock the pipe in position with the rear casing mudguar...

Page 248: ... keep it pulled loosen the coupling 2 and wait for the oil to come out then tighten the coupling 2 and release the lever 5 Repeat this procedure a few times both for the left and the right calliper until the oil is completely drained Loosen the couplings 6 and detach the pipes 7 Loosen the screws 8 and remove the callipers 9 making sure to collect the liquid that could remain inside pipe Do not sp...

Page 249: ...olt 10 and disconnect the brake pipe 11 from the mas ter cylinder Loosen the two screws 12 and remove the full lever 13 During the reassembly position the front brake pipe in the original position with the respective clamps then pour the oil in the reservoir and bleed the system as described in the relevant paragraph ...

Page 250: ... pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily DISASSEMBLY OF THE REAR PADS Remove the safety clip 1 Slide out pin 2 Remove the pads 3 making sure not to damage the pre load clip inside the calliper Do not use the brake pedal while removing the pads ASSEMBLY OF THE REAR PADS ...

Page 251: ...ow points in the direction of rotation of the brake disc Refit the pins and the safety pins Refit the calliper tightening the screws 1 to the specified torque NOTE During the reassembly of the callipers first of all insert the retain ing screws manually then before tightening them to the specified torque keep the lever of the front brake pulled for instance with an elastic Only at this point tight...

Page 252: ...he pads Refit the pads 3 making sure that they are correctly inserted in the seat 4 in the body of the calliper NOTE During the reassembly of the callipers first of all insert the retain ing screws manually then before tightening them to the specified torque keep the lever of the front brake pulled for instance with an elastic Only at this point tighten the retaining screws of the callipers to the...

Page 253: ...se only fluid taken from a sealed container DOT 4 Never reuse brake fluid Avoid the ingress of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damaging the painted parts Do not mix two brands of fluid This would reduce boil over point lead...

Page 254: ...ver 3 with the gaiter After replacing the fluid bleed the system on both callipers and on the master cylinder as described in the relevant paragraph Rear braking system Remove the rubber cap 1 of the valve 2 of the calliper Insert the end of a transparent hose in the valve 2 insert the other end in a container Remove the cover 3 with the respective gaiter of the oil reservoir 4 Press on the brake ...

Page 255: ...eds bleeding Bleeding is also required after changing brake fluid To bleed the front braking system begin with the master cylinder fastened on the handlebar then on the on the calliper the procedure is the same Proceed as follows Take the rubber cover off the bleed valve 1 or 1A Insert the end of a transparent hose in the valve 2 or 2A and the other end in a container with fluid make sure that the...

Page 256: ...til the liquid comes out of the trans parent hose without bubbles Lock the bleed valves to the specified torques Top up the fluid level and refit the rubber gaiter and the cover 3 of the res ervoir 4 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle ...

Page 257: ...ed valve 4 so that the fluid comes out of the hose at the beginning only air will come out then close the valve 4 Release the pedal and wait a few seconds Repeat the process until you see only fluid without bubbles coming out of the hose Tighten the bleed valve to the specified torque and check fluid level 2 in the reservoir before refitting the cap 1 If the bleeding procedure was performed correc...

Page 258: ... 2012 NUDA 900 R 2012 H10880 C H10881 D BRAKES Workshop Manual Ed 11 2011 Periodically check the connecting hoses C and D see Scheduled Mainte nance Chart Section B if they show signs of wear or damage replace them ...

Page 259: ...L1 1 NUDA 900 2013 NUDA 900 R 2013 L1 Workshop Manual Ed 11 2011 BRAKES Section ABS version MY13 only ...

Page 260: ...e calliper L1 10 Removing the front master cylinder L1 11 Removing the rear braking system L1 11 Removing the rear master cylinder L1 12 Removing the rear brake calliper L1 13 Checking brake pads for wear replacing the pads L1 14 Brake fluid replacement L1 17 Fluid replacement and system bleeding L1 17 Changing the front braking system fluid L1 17 Changing the rear braking system fluid L1 18 Bleed...

Page 261: ...ressure in each of the two circuits to prevent the wheels from locking up under braking ABS circuit diagram X Front master cylinder Z Front callipers Y Rear master cylinder W Rear calliper 1 Lines connecting distributor to front brake callipers 2 Line connecting front master cylinder to ABS unit 3 Line connecting ABS unit to front brake calliper distributor 4 Line connecting rear master cylinder t...

Page 262: ...011 7 Front brake lever 8 Front master cylinder 9 Front oil reservoir 10 Right hand front brake calliper line 11 Right hand front brake calliper 12 Left hand front brake calliper 13 Left hand front brake calliper line 14 Right hand front brake disc 15 Left hand front brake disc 16 Front tone wheel 17 Front ABS sensor ...

Page 263: ...25 20 21 H12023 23 19 18 22 Workshop Manual Ed 11 2011 BRAKES 18 Rear brake calliper 19 Rear brake disc 20 Rear master cylinder 21 Rear brake control pedal 22 Rear tone wheel 23 Rear speed and ABS sensor 24 Rear brake fluid reservoir 25 Rear line ...

Page 264: ... thickness wear limit mm 4 0 157 in Rear brake disc diameter mm 265 10 43 in Rear brake disc thickness when new mm 5 0 2 in Minimum disc thickness wear limit mm 4 5 0 177 in Thedistortionofthediscsmustnotexceed0 15mm 0 006in themeasurement should be made with a feeler gauge and a disc installed on the rim To remove the disc from the wheel rim you need to loosen the five retaining screws Onassembly...

Page 265: ...he ABS unit 4 Open the clamp 5 cut the cable tie 6 and remove the immobiliser connec tor 7 Undo the line 2 from the distributor 8 Undo the two screws 9 and remove the ABS unit 4 complete with line 2 and mount 10 Undo the line 2 and the screws 11 to remove the ABS unit Fit the new ABS unit on the mount 10 remove the cap relative to the front feed line and reconnect the line 2 replacing the seal was...

Page 266: ...braking system front or rear Replace the damaged line routing and fastening the new line with clamps and hose guides exactly as before and replacing all the seal washers Fill the system with fluid and bleed as described in the relative paragraph Diagram of location of lines Rear system 1 Line connecting ABS unit to rear brake master cylinder 2 Line connecting ABS unit to rear brake calliper 3 Clam...

Page 267: ...kshop Manual Ed 11 2011 BRAKES Front system 1 Line connecting ABS unit to distributor 2 Line connecting front brake master cylinder to ABS unit 3 Line connecting distributor to right hand front calliper 4 Line connecting distributor to left hand front calliper 5 Hose ring ...

Page 268: ...ake fluid onto any painted surface or lens for example lights lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Removing the front brake calliper Loosen the co...

Page 269: ...the relative paragraph Replace all the seal washers Removing the rear braking system Remove the rear chassis complete with fuel tank and the rear wheel as de scribed in the relative paragraphs To remove the rear braking system the individual components of the system must be separated After separation drain the components of brake fluid as described in the paragraph Changing brake fluid Donotspillb...

Page 270: ...cylinder Unhook the spring 1 loosen the three screws 2 and remove the cover 3 so the master cylinder is free Loosen the screw 4 and remove the oil reservoir 5 In case you need to replace the master cylinder 6 open the clamp 7 and detach the pipe 8 collecting the oil that comes out of the reservoir then loosen the coupling 9 and remove the delivery pipe 10 ...

Page 271: ...the brake calliper 6 collecting any fluid remaining in the line During reassembly refit the rear brake lines in exactly the same positions as before replacing all the seal washers and fastening with the relative clamps as indicated in the paragraph Replacing a brake line and with the relative hose guide then fill the reservoir with brake fluid and bleed the system as described in the relative para...

Page 272: ... pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily DISASSEMBLY OF THE REAR PADS Remove the safety clip 1 Slide out pin 2 Remove the pads 3 making sure not to damage the pre load clip inside the calliper Do not use the brake pedal while removing the pads ASSEMBLY OF THE REAR PADS ...

Page 273: ...pins Refit the calliper tightening the screws 1 to the specified torque NOTE During the reassembly of the callipers first of all insert the retain ing screws manually then before tightening them to the specified torque keep the lever of the front brake pulled for instance with an elastic Only at this point tighten the retaining screws of the callipers to the specified torque This ensures the corre...

Page 274: ...he body of the calliper NOTE During the reassembly of the callipers first of all insert the retain ing screws manually then before tightening them to the specified torque keep the lever of the front brake pulled for instance with an elastic Only at this point tighten the retaining screws of the callipers to the specified torque This ensures the correct positioning between the brake disc and the bo...

Page 275: ...luid taken from a sealed container DOT 4 Never reuse brake fluid Avoid the ingress of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damaging the painted parts Do not mix two brands of fluid This would reduce boil over point leading to lo...

Page 276: ...h the gaiter After replacing the fluid bleed the system on both callipers and on the master cylinder as described in the relevant paragraph Changing the rear braking system fluid Remove the rubber cap 1 of the valve 2 of the calliper Insert the end of a transparent hose in the valve 2 insert the other end in a container Remove the cover 3 with the respective gaiter of the oil reservoir 4 Press on ...

Page 277: ...eds bleeding Bleeding is also required after changing brake fluid To bleed the front braking system begin with the master cylinder fastened on the handlebar then on the on the calliper the procedure is the same Proceed as follows Take the rubber cover off the bleed valve 1 or 1A Insert the end of a transparent hose in the valve 2 or 2A and the other end in a container with fluid make sure that the...

Page 278: ...til the liquid comes out of the trans parent hose without bubbles Lock the bleed valves to the specified torques Top up the fluid level and refit the rubber gaiter and the cover 3 of the res ervoir 4 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle ...

Page 279: ...eed valve 4 so that the fluid comes out of the hose at the beginning only air will come out then close the valve 4 Release the pedal and wait a few seconds Repeat the process until you see only fluid without bubbles coming out of the hose Tighten the bleed valve to the specified torque and check fluid level 2 in the reservoir before refitting the cap 1 If the bleeding procedure was performed corre...

Page 280: ...0 2013 NUDA 900 R 2013 H10881 D H12051 C BRAKES Workshop Manual Ed 11 2011 Periodically check the connecting hoses C and D see Scheduled Mainte nance Chart Section B if they show signs of wear or damage replace them ...

Page 281: ...M 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 M Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Section ...

Page 282: ...tion M 23 Electronic control unit ECU M 23 Spark plug M 24 Battery M 24 Battery charger M 24 Headlight tail light M 25 Headlight adjustment M 25 Front headlamp bulb replacement M 26 Headlight removal M 27 Turning indicator bulb replacement M 28 Tail light replacement M 28 Number plate bulb replacement M 29 Left hand switch MY12 M 30 Left hand switch MY13 M 31 Right hand switch M 32 Right hand swit...

Page 283: ...ELECTRICAL SYSTEM Stand rotative switch replacement M 48 12V plug replacement M 48 Water temperature sensor replacement M 49 Troubleshooting M 50 Charging system M 50 Starting system M 50 Electronic ignition system M 50 Electrical connectors positioning M 51 Important M 54 ...

Page 284: ...M 4 NUDA 900 2012 2013 NUDA 900 R 2012 2013 ELECTRICAL SYSTEM Workshop Manual Ed 11 2011 ...

Page 285: ...013 M 5 H10467 5 6 7 8 10 22 23 24 25 26 27 21 14 9 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 47 46 43 48 50 49 51 52 53 54 55 1 2 3 4 13 11 12 18 15 16 17 19 20 56 Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Wiring diagram MY12 ...

Page 286: ......

Page 287: ...nnector for heated hand grips kit Optional 30 Right hand switch 31 Front brake lever stop microswitch 32 Combined dashboard 33 Front R H turning indicator 34 Headlight 35 Front L H turning indicator 36 Clutch control lever 37 Left hand switch 38 Throttle opening position sensor 39 Injector 1 40 Injector 2 41 Coil spark plug 1 42 Coil spark plug 2 43 Engine ground terminal 44 Gear position sensor 4...

Page 288: ...M 8 NUDA 900 2012 2013 NUDA 900 R 2012 2013 ELECTRICAL SYSTEM Workshop Manual Ed 11 2011 INTENTIONALLY WHITE PAGE ...

Page 289: ...12 2013 M 6 M 9 H12126 1 2 3 4 5 6 7 8 9 10 11 12 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 13 14 20 19 18 17 16 15 Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Wiring diagram MY13 ...

Page 290: ...M 10 NUDA 900 2012 2013 NUDA 900 R 2012 2013 ELECTRICAL SYSTEM Workshop Manual Ed 11 2011 ...

Page 291: ...nt R H turning indicator 34 Headlight 35 Front L H turning indicator 36 Clutch control lever 37 Left hand switch 38 Throttle opening position sensor 39 Injector 1 40 Injector 2 41 Coil spark plug 1 42 Coil spark plug 2 43 Engine ground terminal 44 Gear position sensor 45 Crankshaft position sensor 46 Fuel pump 47 Rear brake pedal stop microswitch 48 Side stand microswitch 49 Exhaust valve actuator...

Page 292: ...11 2011 Electrical component location Generator 1 inside the right hand cover Electronic ignition coils 2 integrated with spark plug cap positioned on the cylinder head Spark plugs on the cylinder head Electronic control unit 3 on the front part in front of the filter box Voltage regulator 4 on a support on the battery ...

Page 293: ... 6 H10474 7 H10475 8 9 Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Starter motor 5 on the front part of the engine Starter relay 6 on the central part behind the battery Throttle opening position sensor 7 on the throttle body Fuel pump 8 inside the reservoir 9 ...

Page 294: ...SYSTEM Workshop Manual Ed 11 2011 Battery 10 12V 12Ah on the central part of the right hand side A 30A fuse 11 on the solenoid starter Relays on the front side near the control unit Relay 12 main Relay 13 electric fan Relay 14 fuel pump Coolant temperature sensor 15 on the rear part of the cylinder head ...

Page 295: ...572 19 17 H10573 18 19 Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Electric fan 16 on the rear part of the radiator Headlamp 17 with H4 12V 55 60W twin halogen lamp and 12V 5W parking light bulb LED tail light 18 Turning indicators 19 12V 6W bulbs Combined dashboard 20 ...

Page 296: ...coil connector from the wiring and measure resistance with a meter 1 Measure across the terminals of the connector 2 correct value is about 0 1 1 0 If resistance is outside the specified limits replace the complete generator Generator performance 12V MAX 390W AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAP TURED BY THE MAGNETS ...

Page 297: ...2 2013 H10935 H10937 Workshop Manual Ed 11 2011 ELECTRICAL SYSTEM Gear position sensor Positioned in the left hand side of the engine under the sprocket casing Crankshaft position sensor Positioned on the rear right hand side of the engine ...

Page 298: ...h moment with a series of sensors The sensors are a crankshaft position sensor pick up an ambient air tempera ture sensor in filter box a coolant temperature sensor a throttle position sensor and a pressure sensor on the throttle body The ignition system is composed of ECU 1 Battery 2 Starter relay 3 Fuse box 4 EFI general relay 5 Ignition 6 Transponder antenna 7 R H switch 8 Clutch lever microswi...

Page 299: ...rging system is composed of Battery 1 Voltage regulator 2 Alternator 3 The alternated current generated by the alternator is converted into direct cur rent by the voltage regulator The voltage regulator serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current ...

Page 300: ...above 3 000 rpm measure voltage across the positive and negative terminal of the battery using a meter the battery must be charged when performing this test If reading is outside a 14 0 14 5 V check generator and voltage regulator as described in the relevant paragraph Voltage regulator inspection With the ignition on and the battery charged 12 5 13 V start the engine if the battery voltage does n...

Page 301: ...rkshop Manual Ed 11 2011 ELECTRICAL SYSTEM Electric starting system The starting system is composed of ECU 1 Battery 2 Starter relay 3 Starter motor 4 Fuse box 5 Ignition 6 Transponder antenna 7 R H switch 8 Clutch lever microswitch 9 Gear position sensor 10 Side stand sensor 11 ...

Page 302: ... circuits during disassembly Disconnect the starter relay connector A Disconnect the starter motor and battery positive cable wires at relay end Ap ply 12 Volts to the terminals 1 and 2 on the relay and check the continuity between the terminals B M Do not apply such voltage to the relay for more than 5 seconds as it could overheat and suffer damage Use a multimeter to establish whether the windin...

Page 303: ...ce of the primary and secondary winding with a me ter Primary winding resistance 0 87 at 20 C WIRING DIAGRAM 1 PIN 1 Vcoll 2 PIN 2 Ground 3 PIN 3 Vbatt 4 High Voltage Electronic control unit ECU Remove the filter box see Chapter E to gain access to the electronic control unit 1 The control unit consist of a microprocessor system that controls the ignition advance according to the signals coming fr...

Page 304: ...dard slow charging cycle 0 6A for 8 hours for 12V 12Ah battery Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle 6A for 0 5 hours for 12V 12Ah battery Battery charger To gain access to the battery 1 remove the protection panel as described in the relevant paragraph first remove the BLACK negative cable then the RE...

Page 305: ...cular to its longitudinal axis In front of a wall or a screen positioned at a distance of 10 metres 32 8 ft draw a horizontal line corresponding to headlight centre height and a vertical line aligned with vehicle longitudinal axis If possible execute this operation in a shaded place When the low beam is on the upper edge between dark and lit zone should be at 9 10th of headlight centre from ground...

Page 306: ...he rubber gaiter 4 turn the ring nut 5 counter clockwise until the bayonet fitting is released then remove it remove the bulb 10 Headlamp bulb 10 is of the halogen type be careful when replac ing it since the glass part shall not be touched with bare hands Make sure that the new bulb is of the HD type Heavy Duty To replace the parking light bulb Loosen the two screws 6 and remove the cover 7 Detac...

Page 307: ...ll connectors Loosen the two front screws 1 Unhook the clutch cable 2 from the fastening Unhook the front brake pipe from the fastening Loosen the two upper screws 3 and lift the support 4 with the turning indica tors Move forward the upper part of the light 5 then lift it unhooking it from the supporting pins During the reassembly reattach both the front brake pipe and the clutch cable after fast...

Page 308: ...t Loosen the screw 1 remove lens 2 and replace bulb 3 pushing it inside and turning it to remove it Once the bulb has been replaced reverse the above procedure to reassemble 12V 6W bulb Tail light replacement The tail light 1 is a LED light if it does not work properly it must be replaced The removal of the tail light is described in Chapter E ...

Page 309: ...lb replacement Loosen screw 1 and remove the number plate bulb 2 from the mudguard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassemble 12V 5W bulb Make sure that the new bulb is of the LL type Long Life ...

Page 310: ...AL SYSTEM Workshop Manual Ed 11 2011 Left hand switch MY12 1 High beam flashing light 2 High beam switch control Low beam switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 Horn Turn Switch Turn Switch Premuto OFF Pressed OFF Horn Switch Horn Switch Car...

Page 311: ...Right hand turning indicators To deactivate the turning indicators press the control lever after it is returned to the centre 4 ABS switch The ABS brake system can be turned on off only when the vehicle is at a standstill and with the key turned to the ON position Press and hold the ABS button for approximately 4 seconds in order to turn the system on off Note When turning the ignition key from th...

Page 312: ... B BL V A V N VI M BI BL V G N V AZ GR BL B AZ N PREMUTO OFF N ELECTRICAL SYSTEM Workshop Manual Ed 11 2011 Turn Switch Turn Switch Premuto OFF Pressed OFF Horn Switch Horn Switch A riposo OFF At rest OFF Premuto ON Pressed ON Dimmer switch Dimmer switch Passing switch Passing switch Tipo Type Stabile Stable Instabile Unstable AZ Light blue Gr Grey N Black Bl Blue B White G Yellow V Green A Orange...

Page 313: ...op Manual Ed 11 2011 ELECTRICAL SYSTEM Right hand switch removal Remove the tool as described in the relevant paragraph Loosen the screws 1 and move the lever master cylinder Disconnect the connector 2 Loosen the front screw 3 and turn the switch 4 loosen the screw 5 then remove the switch 4 ...

Page 314: ...013 H10518 1 2 H10519 4 3 ELECTRICAL SYSTEM Workshop Manual Ed 11 2011 Left hand switch removal Remove the tool as described in the relevant paragraph Disconnect the two connectors 1 and 2 Loosen the two screws 3 and remove the light switch 4 ...

Page 315: ...uxiliary fuses 3 900 900R MY12 Located at the rear of the motorcycle under the saddle Fuse 1 7 5 A Engine control Diagnosis Starting relay Brake light Parking lights Heated hand grips Fuse 2 15 A Headlights Number plate light Horn Turning indicators Instrument panel Fuse 3 15 A Left hand cylinder injector Left hand cylinder ignition Fuse 4 15 A Right hand cylinder injector Right hand cylinder igni...

Page 316: ...Fuse 2 15 A Horn Number plate light Headlight high beam and low beam Stop light Accessories Fuse 3 15 A Left hand cylinder ignition Right hand cylinder ignition Injectors Fuel pump Fuse 4 7 5 A Lambda sensor Fuse 5 10 A Radiator fan Fuse 6 7 5 A Diagnosis Instrument panel Antitheft Turning indicators Battery socket Fuse 7 4 A Parking lights ABS Fuse 8 10 A Engine control To avoid possible short ci...

Page 317: ...onductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage Relay removal Remove the filter box cover as described in the relevant paragraph Loosen the two screws 1 and lift the relay support 2 Remove the connectors from the relays 3 and remove the relays slipping them off upwards ...

Page 318: ...paragraph then remove them 1 Main relay 2 Electric fan relay 3 Fuel pump relay A Set the meter to the Impedance scale and check the energiser coil for proper operation Reading should be 80 Ohm 10 at 20 C B Set the meter to Continuity mode and check the circuit is open C Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes ...

Page 319: ...display This indicates the engaged gear neutral is indicated with this symbol 7 MODE button Vehicle performance can be varied by selecting RAIN mapping The ECU memorises two different mappings that can be selected using the MODE button see specific paragraph The standard configuration delivers maximum engine power The second mapping delivers power than can be used more at low and medium revs and i...

Page 320: ... engine idle and wait for the temperature to decrease scale shown on display and the warning light to go out If the problem persists check the coolant level in the expansion tank If the liquid level is correct contact your HUSQVARNA dealer Neutral warning light GREEN This lights up permanently when the motorcycle is in neutral Engine diagnosis warning light ORANGE This lights up permanently when t...

Page 321: ... Average consumption CLOCK Clock see Clock adjustment 7 This displays the parameter set in the field 6 8 This lights up in sequence from left to right as the coolant temperature increases Clock adjustment The clock must be set when the motorcycle is stationary and the key is set to ON The clock is set to 24 hours Press the S button 1 until the word CLOCK appears on the display Press the S button f...

Page 322: ...tly in use flashes Press the S button once to change the unit of measurement Once you have selected the unit of measurement press the S button for more than 4 seconds to confirm the set data and go onto the next scale The following units of measurement can be set Km mp the display will show the speed in km h or mp h the total distance covered in km or mp the partial TRIP distance covered in km or ...

Page 323: ...S button for more than 4 seconds to reset and start a new count of the litres gallons consumed from when average consumption L 100 km has been reset Changing ECU mapping The vehicle leaves the factory in STANDARD configuration i e with maximum power Motorcycle performance can be changed from STANDARD to RAIN by press ing the M button 1 on the dashboard The map can be changed when the vehicle is mo...

Page 324: ...ay support as described in the relevant paragraph Lift the control unit 1 removing it from the guides Disconnect the connector 2 pressing with a screwdriver the tooth 3 and turning the locking element 4 Remove the rubber protection 5 Refit a new control unit proceeding in the reverse order To replace the part use the diagnostic tool and follow the guided procedure ...

Page 325: ...ecial wrench Lift the block 2 and disconnect the block connector 3 and the alarm system connector 4 Refit a new starter block proceeding in the reverse order To replace the part use the diagnostic tool and follow the guided procedure Combined dashboard replacement For the disassembly and reassembly procedures of the combined dashboard see Chapter E For the replacement of the part use the diagnosti...

Page 326: ...hop Manual Ed 11 2011 Rear stop microswitch replacement Loosen the three screws 1 Remove the spring 2 and remove the cover 3 Loosen the three screws 4 remove the upper part 5 Disconnect connector 6 and remove the microswitch 7 Clutch microswitch replacement Remove the connector 1 Loosen the screw 2 and replace the microswitch 3 ...

Page 327: ... the relevant paragraph Loosen the two screws 1 and remove the brake lever Lift the microswitch 2 to remove it Disconnect the connector 3 Install a new microswitch inserting it with pressure in its seat Speed sensor replacement Remove the fuel tank as described in the relevant paragraph Loosen the screw 1 Remove the fastening from the harness 2 Disconnect the connector 3 Replace the sensor 4 and r...

Page 328: ...agraph Loosen the nut 1 and remove the switch 2 from the stand Remove the fastening from the harness 3 Disconnect the connector 4 Replace the switch 2 during the reassembly insert the switch tab 5 in the hole 6 of the stand and the upper part of the switch in the centring pin 7 12V plug replacement Remove the fuel tank as described in the relevant paragraph Disconnect the connector 1 Loosen the ri...

Page 329: ...Manual Ed 11 2011 ELECTRICAL SYSTEM Water temperature sensor replacement Removethereservoirandbleedthecoolingsystemasdescribedintherelevant paragraph Unhook the connector retainer 1 and remove the connector Loosen the sensor 2 replace and tighten it to torque see Chapter F4 ...

Page 330: ...faulty voltage regulator see paragraph Voltage regulator inspection 2 defective battery see paragraph Battery Starting system If the starter motor does not start this might be a symptom of 1 faulty starter relay see paragraph Starter relay inspection 2 loose starter motor cable 3 faulty starter motor see paragraph Starter motor inspection 4 flat battery see paragraph Battery charger Electronic ign...

Page 331: ...e found 1 Left hand switch connectors 2 Headlight connector 3 Dashboard connector 4 R H turning indicator connector 5 Front stop microswitch connector 6 L H turning indicator connector 7 Right hand switch connector On the right hand side of the bike the following connectors are to be found 8 TPS connector 9 Filter box stepper motor connector 10 Electric fan connector 11 Crankshaft position sensor ...

Page 332: ...nsor connector 14 Fuel pump connector 15 Diagnosis connector 16 Alarm system installation connector 17 Tail light connector 18 Number plate light and turning indicators connector 19 Fuses In the area below the reservoir and filter box the following connectors are to be found 20 Relay connectors 21 Alarm system connector 22 Ignition connector 23 Control unit connector 24 Coil 1 connector 25 Coil 2 ...

Page 333: ... In the central area behind the cylinder block the following connectors are to be found 28 12 volt plug connector 29 Water temperature sensor connector 30 Lambda sensor connector 31 Stand rotative switch connector 32 Speed sensor connector 33 Exhaust valve actuator connector 34 Solenoid starter connector 35 Voltage regulator connector ...

Page 334: ... following parts from water a Rear opening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings In addition to these precautions NEVER ALLOW HIGH PRESSURE AIR OR WATER to get in contact with any ELECTRICAL PARTS the FUEL INJEC TION SYSTEM and especially the electronic control unit 1 and the digital dashboard 2 ...

Page 335: ...N 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 N Workshop Manual Ed 11 2011 ENGINE COOLING Section ...

Page 336: ...N 2 NUDA 900 2012 2013 NUDA 900 R 2012 2013 ENGINE COOLING Workshop Manual Ed 11 2011 Sommario Coolant level check N 3 Coolant replacement N 3 Cooling circuit N 6 Servicing the engine cooling system N 7 ...

Page 337: ...agraphs Do not remove the radiator cap 2 since all the liquid in the expan sion tank 1 will flow out Remove the cap 3 and add the fluid needed to restore the level to the ex pansion tank 1 for the type of liquid to use see the paragraph Technical data Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water Coolant replacement Put the motorbike in a ve...

Page 338: ... that connects the radiator 4 to the exchanger 5 Remove the exchanger pipe 3 and let the coolant drain in the bucket during the reassembly replace the seal 6 Open the clamps 7 and remove the pipes 8 from the radiator allowing the coolant to drain fully from the radiator Reassemble all previously removed components in the reverse order Put the motorbike on the side stand ...

Page 339: ... bor der Refit the radiator cap 9 Start the engine and leave it on until the radiator is warm then turn off the engine and leave it to cool down for around 2 3 minutes Turn the radiator cap 9 until the 1st safety notch and let the possible pres sure discharge then remove the cap Top up with coolant until the maximum level of the radiator cap upper bor der Restart the engine and repeat the procedur...

Page 340: ...Cooling circuit The forced circulation cooling system uses a centrifugal pump located to the right of the cylinder head and two downdraft radiators 1 Radiator cap 2 Radiator 3 Expansion tank 4 Expansion tank cap 5 Water pump 6 Delivery coupling 7 Intake coupling 8 Cooling fan 9 Reservoir radiator connection pipe ...

Page 341: ... avoid damage to radiator Straighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling...

Page 342: ......

Page 343: ...d or work itself loose causing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accord ance with thread diameter pitch and specific application These figures are obta...

Page 344: ...pport to headlight 2 0 Headlight to steering head 5 0 Front L H indicator to dashboard support 1 0 Front R H indicator to dashboard support 1 0 Front mudguard to fork 5 0 Chain protection to swinging arm 8 0 Saddle support bracket to small chassis 5 0 Number plate holder to small chassis 5 0 Tools support bowl to small chassis 2 0 Tail to small chassis 2 0 Front mudguard tail fastening 2 0 Headlig...

Page 345: ...light to number plate holder 5 0 Current plug to support 3 5 Chain slider to chassis 4 0 Steering nut 80 0 S Upper fork locking 19 0 S Headlight pins to bottom yoke 8 0 Rear brake fluid reservoir to chassis 2 0 Rear brake lever to chassis 38 0 S Shock absorber to chassis 75 0 S Shock absorber to swinging arm 45 0 S Key block to chassis 19 0 Steering lock to R H chassis 1 5 Steering lock to L H cha...

Page 346: ...0 0 S BASE version brake pipe to front calliper 16 6 S BASE version brake pipe to front calliper 16 6 S Brake bleed valve to front calliper 8 0 R version brake pipe to front calliper 20 0 S R version brake pipe to front calliper 20 0 S Brake pipe to rear pipe 10 0 S Brake pipe to rear calliper 20 0 S Rear wheel retaining nut 100 0 S Sprocket to engine 50 0 Loctite 243 S Exhaust pipe to engine head...

Page 347: ... to chassis lower L H 38 0 step 3 S Swinging arm shaft 100 0 step 4 S Engine to chassis front R H 66 0 step 5 S Engine to chassis central R H 38 0 step 6 S Engine to chassis lower R H 38 0 step 7 S Steering ring nut First tightening 15 0 step 1 S Loosen 60 step 2 S Final Tightening 10 0 step 3 S Sprocket to sprocket holder Pre tightening sprocket to support 10 0 step 1 Final tightening sprocket to...

Page 348: ...to fork 8 0 ABS unit mount to frame 8 0 Distributor to steering base 8 0 ABS brake line distributor 24 0 S Brake line to ABS unit 24 0 S Brake line to front master cylinder 24 0 S Brake line to rear calliper 24 0 Brake line to distributor 24 0 S Brake line to dual distributor 24 0 S Brake line to left hand front calliper 24 0 Brake line to right hand front calliper 24 0 ABS unit to mount 8 0 ...

Page 349: ... 4 Kgm 3 ft lb Steel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb Steel screws on plastic with metal spacers M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb Steel screws on brass copper aluminium M8 16 Nm 1 6 Kgm 11 8 ft lb Steel sc...

Page 350: ......

Page 351: ...Y 1 NUDA 900 2012 2013 NUDA 900 R 2012 2013 Y Workshop Manual Ed 11 2011 CHASSIS AND WHEELS Section ...

Page 352: ...brication points lubricant Y 3 Front wheel Y 5 Removing the front wheel Y 7 Refitting the front wheel Y 8 Rear wheel Y 10 Removing the rear wheel Y 11 Wheel axle warpage Y 12 Axle runout over 100 mm Y 12 Wheel rim warpage Y 12 Rear chain sprocket secondary drive sprocket and chain Y 13 Checking sprocket wear Y 13 ...

Page 353: ... The chassis is a tubular steel trellis type with stainless steel removable rear small chassis In case of violent shocks or accidents if you think that the chassis might be bent or damaged proceed with an im mediate inspection and if necessary replace it Lubrication points lubricant 1 Steering bearings grease ...

Page 354: ...Y 4 NUDA 900 2012 2013 NUDA 900 R 2012 2013 H10885 A A A A A A H10886 C B B B C C C D CHASSIS AND WHEELS Workshop Manual Ed 11 2011 ...

Page 355: ...ND WHEELS Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING SCREWS B REAR CHASSIS MOUNTING SCREWS C FOOTREST PINS SPRINGS D PASSENGER FOOTREST MOUNTING SCREWS Front wheel 1 Tyre 2 Rim 3 Bearings 4 Sealing rings 5 Inner spacer 6 Outer spacer 7 Wheel axle 8 Brake discs ...

Page 356: ...00 R 2012 2013 H12059 MY13 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 8 1 4 1 3 CHASSIS AND WHEELS Workshop Manual Ed 11 2011 1 Tyre 2 Rim 3 Bearings 4 Sealing rings 5 Inner spacer 6 Outer spacer 7 Wheel axle 8 Brake discs 9 Tone wheel ...

Page 357: ...AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground Loosen the screws 1 to remove the callipers Loosen the two screws 2 on the right hand fork leg that lock the pin From the right hand side loosen the pin 3 extract it and remove the wheel 4 ...

Page 358: ...0892 1 3 H10893 2 H10890 3 CHASSIS AND WHEELS Workshop Manual Ed 11 2011 Refitting the front wheel Refit the wheel 1 in the fork making sure that you position the spacer 2 on the left hand side of the wheel Insert the pin 3 and tighten it to torque ...

Page 359: ...allipers first of all insert the retain ing screws manually then before tightening them to the specified torque keep the lever of the front brake pulled for example with an elastic Only at this point tighten the retaining screws of the callipers to the specified torque This ensures the correct positioning between the brake disc and the body of the calliper avoiding thus that the pistons work incor...

Page 360: ...10 11 12 13 14 4 5 6 CHASSIS AND WHEELS Workshop Manual Ed 11 2011 Rear wheel 1 Tyre 2 Rim 3 Inner spacer 4 Bearings 5 Elastic rings 6 Sealing rings 7 Outer spacer 8 Phonic wheel 9 Outer spacer 10 Cush drive dampers 11 Sprocket holder hub 12 Spacer 13 Sprocket 14 Brake Disc ...

Page 361: ...unchanged after reassembly Remove the chain 4 and remove the full wheel paying attention to the spacers on the sides of the hub For reassembly follow the removal procedure in the reverse order by inserting the brake disc in the calliper Check the cush drive dampers for wear 5 if only one of the ap pears to be damaged all of them must be replaced Do not operate the rear brake pedal when the wheel h...

Page 362: ...le Standard Max limit Wheel axle less than 0 1 mm 0 2 mm 0 079 in less than 0 039 in PIN FRONT Wheel rim warpage The table below reports the allowed limits for wheel rim warpage An excessive side runout and out of round are generally caused by worn out bearings In these cases replace the bearings and the sealing rings If this does not solve the problem change the wheel rim or the wheel Standard Ma...

Page 363: ...dingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the six nuts 1 that retain it to the cush drive damper Chain and sprockets must always be replaced as a set Checking sprocket wear Check the transmission sprocket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnorma...

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