Husqvarna NUDA 900 R (2012), NUDA 900 (2012), NUDA 900 (2013), NUDA 900 R (2013) Workshop Manual
NUDA 900 2012/2013
NUDA 900 R 2012/2013
Workshop Manual Ed. 11-2011
Rev 02
Revision Record
Rev. No. Date Page Description
01 30/03/2012 A.5 "Cold tyre pressure - Rear" value corrected.
02 23/10/2012 All pages Inserted MY13 (section L excluded).
02 08/11/2012 D.18 Added value in the table.
02 08/11/2012 D.19 Applied change.
02 08/11/2012 D.25 Inserted text.
02 23/10/2012 F4.13 H10465 correct drawing in H12017.
02 08/11/2012 I.8 Added value in the table; applied change.
02 23/10/2012 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 modiced drawing in H12123.
02 08/11/2012 M.21 H10942 modiced 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 reect on-going product development. Illustrations in the manual may differ from
actual components. No reproduction in full or in part without written authorisation.
st
1
edition (11-2011) - Rev. 02
FOREWORD, TABLE OF CONTENTS
simbolo
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Workshop Manual
NUDA 900 2012/2013
NUDA 900 R 2012/2013
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
1st edition (11-2011) - Rev. 02
Printed in Italy
MODELS COVERED (from serial number onwards)
NUDA 900: ZKHA700A#CV000001
NUDA 900 R: ZKHA700B#CV000001
1. Chassis serial number
Workshop Manual Ed. 11-2011
a.1
FOREWORD, TABLE OF CONTENTS
simbolo
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Foreword
This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance
and repair of the models covered in this manual. The technical information provided in this manual is a critical complement to operator training and operators should become thoroughly familiar with it.
This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical
preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally
omitted as it was considered superuous. The technicians must adopt special safety procedures that they will deem
necessary in order to prevent damages to the motorbike, to its components, and to people.
For ease of understanding, diagrams and photographs are provided next to the text.
Notes with special signicance are identied 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 effective service work, observe the following HUSQVARNA recommendations:
– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify
problem symptoms;
– diagnose the problem and identify the causes clearly. This manual provides basic background information that must
be supplemented with the operator's expertise and specic training available through HUSQVARNA held at regular
periods;
– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;
– avoid unnecessary disassembly work to get to the part that needs repairing.
Always read the relevant instructions and follow the disassembly sequence outlined in this manual.
Workshop Manual Ed. 11-2011
a.2
FOREWORD, TABLE OF CONTENTS
simbolo
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Table of Contents
Title Section
Foreword, Table of Contents ...............................................................................a
Important Notices ................................................................................................b
General Information
Maintenance ........................................................................................................B
Troubleshooting
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 gures ........................................................................................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 System ................................................................................................M
Engine Cooling ................................................................................................... N
Tightening Torque Figures ...................................................................................X
Chassis and Wheels ............................................................................................Y
.............................................................................................A
.................................................................................................. C
NOTES
Unless otherwise specied, data and specications apply to all models.
a.3
Workshop Manual Ed. 11-2011
IMPORTANT NOTICES
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Section
b
b.1
Workshop Manual Ed. 11-2011
IMPORTANT NOTICES
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
GENERAL SAFETY WARNINGS
Read these general recommendations carefully before using the vehicle.
Carbon monoxide
Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction
system.
Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even
death if inhaled.
Parts of the vehicle that become hot
Before working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very
hot and remain hot for some time after turning off the engine.
Risk of burns - work with caution and wear suitable PPE if necessary.
Fuel
The fuel used to power internal combustion engines is highly ammable and explosive.
Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not
smoke and avoid contact between the fuel and naked ames, sparks, etc. that may cause an explosion.
Do not dispose of fuel in the 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 inammable and if burnt, produce invisible ames 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 containers in areas accessible to children and animals since it is toxic.
DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding.
Engine oil
Do not dispose of oil in the environment since it is highly polluting.
Keep out of reach of children.
Wear latex gloves since prolonged contact with the skin can cause serious damage.
Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where
the vehicle will be used.
Brake uid
Brake uid is highly corrosive and may damage the rubber and painted parts of the vehicle.
While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves.
In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice
immediately.
Keep out of reach of children.
Workshop Manual Ed. 11-2011
b.2
1
2
IMPORTANT NOTICES
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Battery
Recharge the battery in well ventilated areas since the battery produces toxic, highly inammable gases when being
recharged; do not smoke or use naked ames or sparks.
The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water.
It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage
to the eyes.
If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally , drink
plenty of water or milk.
In all cases, seek medical advice immediately.
The battery liquid is corrosive and should not be poured onto the painted or rubber parts.
The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery
to the special authorised recycling centres in accordance with the legal requirements in force in the country where
the vehicle will be used.
Keep out of reach of children.
H10571
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 observed.
* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must
follow the maintenance programme indicated in Section B by having the required
maintenance inspections carried out at authorised HUSQVARNA dealers. The
cost for cha nging par ts and for t he labour nec essar y in ord er to comply w ith
the maintenance p lan is char ged to the Cli ent. The war ranty b ecome s NULL
AND VOID if the motorcycle is rented.
Notes
Left and right side is determined when seated on motorcycle.
Z: number of teeth
A: Austria
AUS: Australia
B: Belgium
BR: Brazil
CDN: Canada
CH: Switzerland
D: Germany
E: Spain
F: France
FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America
Unless otherwise specied, data and instructions apply to all market variants.
Workshop Manual Ed. 11-2011
b.3
IMPORTANT NOTICES
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
RECOMMENDED SHOP PRACTICES
Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or
foreign bodies.
- Put the vehicle in a well lit area;
- Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts.
- Use suitable equipment for lifting/removing heavy parts.
- Use appropriate keys (not pliers) to loosen/tighten nuts and screws.
- When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the specied torque
and follow a cross pattern or a dedicated pattern as outlined in the relevant section.
- Always mark any parts or positions that might be confused upon assembly.
- Use special tools where specied.
- Clean thoroughly the removed components before retting them
- During the reassemb ly, make sure that the bearin gs turn f reely wi thout obs truc tion o r without g ettin g stuck, ot her wise r eplace
them
- Always replace the sea ls, the se aling r ings , the spli t pins, th e screw s with da mage d threa d, and the s elf- lo cki ng nuts w ith new
parts.
- Use genuine HUSQVARNA parts and the recommended lubricant brands.
- At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer.
Electrical parts
- Disconnect the electrical component connectors by pressing the special safety hooks.
- Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products.
- Make sure that the cables are correctly seamed to the connector terminals.
- When you reconnect the connectors, ensure the correct coupling.
Do not disconnect the connectors by pulling the electrical cables.
- Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read them.
Where not specied, ret the previously removed components following the procedures in the reverse order with
respect to the removal.
Workshop Manual Ed. 11-2011
b.4
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Section
A
A.1
Workshop Manual Ed. 11-2011
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Sommario
Engine ..........................................................................................................A.3
Timing system ..............................................................................................A.3
Lubrication ....................................................................................................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
Rear brake ....................................................................................................A.5
Rims
Tyres .............................................................................................................A.5
Weight, capacity
Table for lubrication, supplies .......................................................................A.5
Electrical components location .....................................................................A.6
Dimension.....................................................................................................A.7
...................................................................................................A.4
.............................................................................................................A.5
...........................................................................................A.5
Workshop Manual Ed. 11-2011
A.2
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Engine
Type
....................... inline twin cylinder, 4 stroke, with four valves per cylinder
Cooling
Bore ......................................................................................... 3,31 in. (84 mm)
Stroke ...................................................................................... 3,19 in. (81 mm)
Displacement
Compression ratio
Starting ..................................................................................................electric
Type of fuel
Timing system
type
4 valves per cylinder
Valve clearance (with engine cold)
Intake .........................................................0,0091 ÷ 0,013 in. (0.23 ÷ 0.33 mm)
Exhaust...................................................0,0118 ÷ 0,0161 in. (0.30 ÷ 0.41 mm)
.............................................................................liquid and electric fan
........................................................................ 54,8 in3 (898 cm3)
......................................................................................13:1
............................................................. unleaded fuel 95ROZ/RON
................................................ double overhead camshaft chain operated;
Lubrication
...........................................................dry sump oil circuit with built-in tank,
type
cartridgelterandoil/waterheatexchanger
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
Driven gear on clutch housing .................................................................... Z 68
Transmission ratio ....................................................................................1.943
Clutch
..........................................oil bath multiple disc clutch, mechanical control
type
Transmission
type
.............................................................................constant mesh gear type
............................................................................ Z 35
Transmission ratio
1st gear.........................................................................................2.462 (32/13)
2nd gear .......................................................................................1.750 (28/16)
3rd gear ........................................................................................1.381 (29/21)
4th gear ........................................................................................1.174 (27/23)
5th gear ........................................................................................1.042 (25/24)
6th gear ........................................................................................0.960 (24/25)
A.3
Workshop Manual Ed. 11-2011
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Secondary drive
transmission sprocket (NUDA 900) ...........................................................Z 17
Transmission sprocket (NUDA 900 R) ........................................................ Z 16
Rear wheel sprocket ................................................................................... Z 42
Transmission ratio (NUDA 900) ...................................................................2.47
Transmission ratio (NUDA 900 R) .............................................................2.625
Transmission chain dimensions
FINAL RATIOS
NUDA 900
1st gear....................................................................................................11,815
2nd gear
3rd gear
4th gear .....................................................................................................5,634
5th gear .....................................................................................................5,000
6th gear
NUDA 900 R
1st gear....................................................................................................12,557
2nd gear
3rd gear
4th gear
5th gear
6th gear
....................................................................................................8,398
.....................................................................................................6,627
.....................................................................................................4,607
....................................................................................................8,925
.....................................................................................................7,043
.....................................................................................................5,987
.....................................................................................................5,314
.....................................................................................................4,896
.............................................5/8” x 5/16” (525)
Chassis
type
............................... tubular steel trellis with removable steel rear chassis.
Front suspension
NUDA 900
Type upside-down hydraulic fork
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
.................................................................direct with hydraulic monoshock
Type
(adjustable spring preload and hydraulic rebound damping)
Wheel travel........................................................................... 7,09 in. (180 mm)
NUDA 900 R
Type .................................................................direct with hydraulic monoshock
(adjustable spring preload and hydraulic compression
and rebound damping; adjustable length)
Wheel travel........................................................................... 7,09 in. (180 mm)
...................................1,89 in. (ø 48 mm) legs
Front brake
.....................................................twinoatingdiscø12,6in.(ø320mm)
Type
with radial pump and radial callipers
Workshop Manual Ed. 11-2011
A.4
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Rear brake
Type ...............................xeddiscø10,43in.(ø265mm)andoatingcalliper
Rims
Front .................................................................................in light alloy: 3.5”x17”
Rear ..................................................................................in light alloy: 5.5”x17”
Tyres
............................................................................................120/70xZR17”
Front
Rear .............................................................................................180/55xZR17”
Cold tyre pressure
Front ................................................................................32,71 psi (2.3 kg/cm2)
Rear .................................................................................41,25 psi (2.9 kg/cm2)
Weight, capacity
Kerb weight, without fuel.
Dry weight...............................................................................383,6 lb. (174 kg)
Fuel tank capacity reserve included ...........................................2,86 Imp. Gall
3,43 U.S. Gall. / 13 l
Fuel reserve...................................................................approx. 0,66 Imp. Gall.
approx. 0,79 U.S. Gall.
approx. 3 l
Coolant tank capacity .................................................................0,31 Imp. Gall.
0,37 U.S. Gall.
1.4 l
Transmission oil
Oilandoillterreplacement ....................................................... 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
......................................................407,85 lb (185 kg)
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 .....................................CASTROL MOTORCYCLE COOLANT
Brakeuid...........................................CASTROL RESPONSE SUPER DOT 4
Grease lubrication
Secondary drive chain lubrication................CASTROL CHAIN LUBE RACING
Front fork oil.............................................................TITAN SAF 1091 (FUCHS)
Rear shock absorber oil............................SYNTHETIC FORK OIL SAF 1091 *
Electric contact protection ......................CASTROL METAL PARTS CLEANER
* NOTE: Only an authorised Ohlins centre can service the rear shock absorber of the R version.
....................................................CASTROL LM GREASE 2
Workshop Manual Ed. 11-2011
A.5
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Electrical components location
The ignition system includes the following elements:
- Generator on the inner side of R.H. crankcase half cover;
- Electronic ignition coil with integrated spark plug cap positioned on cylinder head;
- Electroniccontrolunitonthefrontpartinfrontofthelterbox;
- Spark plugs on the cylinder heads;
- Starter motor in front of the cylinders@ block;
- Solenoid starter on the central part behind the battery;
- Potentiometer on throttle 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;
- Turningindicatorasherintegratedinthedigitalinstrument;
- Relay for fuel pump, general relay and fan positioned on the front part in front of the control unit;
- Electric fan;
- Secondary fuses positioned on the rear part under the saddle; two 30A main fuses on the solenoid starter;
- Coolant temperature sensor on the cylinder head;
- Lambda sensor;
- Headlamp with H4-12V-55/60W halogen bulb and 12V-5W parking light bulb;
- LED tail light with stop light bulb;
- 12V-10W turning indicator bulbs;
- Fuel pump inside the tank.
- Multifunction digital instrument.
Workshop Manual Ed. 11-2011
A.6
GENERAL INFORMATION
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
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)
1220 mm
A
195 mm
1495 mm
2190 mm
893 mm
A.7
H10575
Workshop Manual Ed. 11-2011
MAINTENANCE
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Section
B
B.1
Workshop Manual Ed. 11-2011
MAINTENANCE
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
ENGINE
Check engine oil level
Replace engine oil together with oil lter,
clean magnetic plug M24x2
Check / adjust valve play
Replace spark plugs
Check coolant level
Replace coolant
Check / adjust clutch play
SERVICE
COUPON
After the
rst
1.000 Km
X X X X X
X X X X X
X
X X X X X
SERVICE
COUPON
EVERY
10.000 Km
SERVICE
COUPON
EVERY
20.000 Km
X X
X X
X X
SERVICE
COUPON
EVERY
30.000 Km
SERVICE
COUPON
EVERY
40.000 Km
EVERY
1.000 Km
EVERY
10.000 Km
or
ONCE A
YEAR
EVERY
20.000 Km
EVERY
20.000 Km
EVERY
1.000 Km
EVERY
20.000 Km
or
EVERY 2
YEARS
EVERY
1.000 Km
Workshop Manual Ed. 11-2011
B.2
MAINTENANCE
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
CHASSIS
CHECKS SERVICE
COUPON
EVERY
1.000 Km
After the
rst
1.000 Km
Check and lubricate secondary chain
Lubricate the secondary drive chain at least once every 1,000 km.
If used on dusty or wet roads, do this more frequently
Check front/rear sprockets for wear: if ne-
cessary, replace along with the secondary
X X X X X X
drive chain
Air lter
Second.Drive chain: check tension and
(1)
wear
X, L X, L X, L X, L X, L X, L
X X R X R
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 uid
Coolant
(2)
(2)
X X X X X X
X X X X X X
Light alignment
Cush drive dampers X X
Tyres: pressure / wear X X X X X
Wheels X X X X
Overall tightening of nuts and bolts X X X
Side stand X L L L L L
Suspension and alignment X X X
Fuel hoses
(3)
Brake pad wear X X X X X X
Check cooling-water tubes and water
pump for condition and leakage / replace
if necessary
X: Inspect and clean, adjust, lubricate or replace if necessary.
R: Change.
L: Lubricate.
(1):
Check and clean, adjust or replace if necessary every 1,000 km.
(2):
Replace every 2 years.
(3):
Replace every 4 years.
SERVICE
COUPON
EVERY
10.000 Km
SERVICE
COUPON
EVERY
20.000 Km
SERVICE
COUPON
EVERY
30.000 Km
X
X X X X
Workshop Manual Ed. 11-2011
SERVICE
COUPON
EVERY
40.000 Km
X
B.3
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Section
C
C.1
Manuale d'officina Ed. 11-2011
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
ENGINE
Trouble Possible causes Remedy
Ignition switch not in ON position Switch ignition switch to position ON
Engine-stop-switch on OFF position Switch to position ON
Starter motor does not operate or does not
turn engine over
Engine turns over but does not start engine
or starts hard
Discharged battery, loose or corroded
connections
Ignition circuit in short-circuit Check ignition circuit
Starter motor defect Replace starter motor
Spark plugs loose Tighten spark plugs
Spark plugs not according to specications
or defective
Spark plugs fouled or wet Clean or exchange
Battery nearly discharged, starting rpm
too low
Fuel supply inadequate
Valve clearance below specication
Valve timing incorrect Adjust position of camshaft gears
Ignition coil or ignition cable defective Check / replace
Ignition unit defective, ignition timing in-
correct
Cylinder gasket defective Exchange cylinder head gasket
Valves and valve guides worn or imperfect
valve seat
Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder
Engine oil too heavy (winter operation) Exchange engine oil
Check/replace battery and check connections, check charging system
Replace spark plug
Check/replace battery and check connections, check if battery is charged by
generator
Check fuel tank if empty
Check / replace fuel lter, fuel supply pipes, fuel pump, fuel pressure sensor and
injectors
Adjust valve clearance according to spe-
cication
Check / replace crank position trigger and
ECU
Exchange valves, rework valve seats or
exchange cylinder head
Manuale d'officina Ed. 11-2011
C.2
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Trouble Possible causes Remedy
Excessive spark plug electrode gap Exchange spark plug
Adjust valve clearance according to spe-
cication
Tighten intake socket or exchange if necessary
Check / replace crank position trigger and
ECU
Check fuel pressure sensor, fuel pump and
fuel supply
Replace spark plug
Adjust valve clearance according to spe-
cication
Check / replace ignition coil
Check / replace crank position trigger and
ECU
Check fuel pressure sensor, fuel pump and
fuel supply
Exchange piston rings and/or cylinder
Engine runs irregularly at idle
Engine runs irregularly at higher speed
Engine has no or insufcient performance
Valve clearance below specication
Intake socket not tight or leaking
Ignition unit defective, ignition timing in-
correct
Valves leaking Rework valve seats
For other possible causes see also "Engine
starts over but does not start engine or
starts hard"
Fuel pressure too low
Leak air Check / replace intake socket
Camshafts worn Check and replace if necessary
For other possible causes see also "Engine
starts over but does not start engine or
starts hard"
Leak air, intake system leaking Check / replace intake socket
Spark plugs not according to specications
or defective
Valve clearance not according specica-
tion
Valve timing incorrect Adjust position of camshaft gears
Ignition coil supplies insufcient ignition
voltage
Ignition unit defective, ignition timing in-
correct
Valves leaking Exchange valves, rework valve seats
Clutch slipping See remedies "clutch is slipping".
Fuel pressure too low
Air lter dirty Exchange
Exhaust system defective Exchange
Excessive Blow-by gases, Piston rings and/
or cylinder bore worn
Engine oil not according to specications Exchange engine oil
C.3
Manuale d'officina Ed. 11-2011
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Trouble Possible causes Remedy
Fuel of too low octane number
Spark plugs not according to specications
Engine knocks or pings
Engine overheats
Engine temperature is too low Thermostat defective Replace thermostat
Engine produces excessive blue smoke or
engine uses too much oil
Engine vibrates
Engine oil quantity increases
or defective
Leak air, intake system leaking
Ignition unit defective, ignition timing in-
correct
Not enough coolant in cooling system, coo-
ling system leaking, air in cooling system
Cooling fan motor defective Replace cooling fan motor
Not enough engine oil in the engine Rell oil
Radiator dirty Clean radiator
Thermostat defective Replace thermostat
Ignition unit defective, ignition timing in-
correct
Water pump, water pump drive defective
Oil pump or oil pump drive defective, re-
taining ring for oil pump gear not tted, oil
circuit blocked
Cylinder head gasket defective Exchange cylinder head gasket
Leak air Check / replace intake socket
Too much oil in the engine (oil in the airbox)
Cylinder head gasket leaking Exchange cylinder head gasket
Valve stem seals leaking Exchange valve stem seals
Oil diluted with fuel / Piston rings and/or
cylinder bore worn
V-ring on water pump drive gear worn/
missing
Oil diluted with fuel / motocycle is only used
in short distances (cold engine)
Engine xation into frame loose Tighten engine xation
Bearing or bearing seat worn Replace bearing or worn component
Oil diluted with fuel / motocycle is only used
in short distances
Oil diluted with fuel / Piston rings and/or
cylinder bore worn
Use fuel of specied octane number (min.
ROZ 95)
Replace spark plug
Check / replace intake socket and intake
system
Check / replace crank position trigger and
ECU
Rell coolant, check system under pres-
sure
Check / replace crank position trigger, ECU
and sensors
Repair water pump, check and renew water
pump drive
Exchange oil pump or oil pump gears,
assemble retaining ring for oil pump gear,
clean oil circuit
Drain engine oil
Exchange piston rings and/or cylinder
Replace V-ring
Use motorcycle at long distances in
between
Use motorcycle at long distances in
between
Exchange piston rings and/or cylinder
Manuale d'officina Ed. 11-2011
C.4
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Trouble Possible causes Remedy
Not enough engine oil in the engine Rell oil
Low or no engine oil pressure
High engine oil pressure
Pressure regulating piston blocked (bypass
valve stuck in opened position)
Oil pump and/or oil pump drive defective
Ignition cover gasket leaking into inside of
engine (leakage of oil pressure circuit)
Oil pump worn Replace oil pump
Oil diluted with fuel / Piston rings and/or
cylinder bore worn
Oil diluted with fuel / motocycle is only used
in short distances
Oil sieve / oil lter dirty/blocked
Pressure regulating piston blocked (bypass
valve stuck in closed position)
Oil circuit blocked Clean oil ducts
Check/replace pressure regulating piston
Check / replace oil pump and/or oil pump
drive
Replace ignition cover gasket and tighten
ignition cover with correct touque
Exchange piston rings and/or cylinder
Use motorcycle at long distances in
between
Clean / replace oil sieve and replace oil
lter
Check/replace pressure regulating piston
C.5
Manuale d'officina Ed. 11-2011
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Trouble Possible causes Remedy
Noise is heard when the engine is
started:
Sprag clutch, sprag clutch housing or freewheel gear worn
Teeth of starter motor and/or starter drive
gears worn
Chain tensioner does not work
Noise seems to come from the valve
train:
Excessive valve clearance
Chain tensioner does not work Replace chain tensioner
Camshaft or brackets of camshaft worn Replace camshafts and/or cylinder head
Camshaft drive worn or loose Tighten or replace camshaft gears
Camshaft chain, chain guide or chain tension
guide worn
Noise seems to come from the piston:
Replace Sprag clutch, sprag clutch housing
or freewheel gear
Replace starter motor and/or starter drive
gears
Noise disappears after the engine is started
when oil pressure is available
Adjust valve clearance according to spe-
cication
Replace camshaft chain, chain guide or
chain tension guide
Engine excessively noisy
Piston or cylinder worn Replace piston or cylinder
Piston pin bore or piston pin worn Replace piston pin bore or piston pin
Piston rings broken or ring grooves worn
Noise seems to come from the crankshaft
or balancing swing arm or crankcase:
Bearings of crankshaft or conrods worn
Needle bushing and /or bearings of balan-
cing swing arm and/or balancing rod worn
Noise seem to come from the clutch or
clutch side:
Friction plates (hammer heads) and/or
clutch drum worn
Excessive or insufcient backlash of the
teeth of the primary drive gears
Clutch drum, clutch hub or pressure plate
worn
Bearing of clutch gear worn Replace primary drive assy.
Disk springs of primary drive assy. worn Replace primary drive assy.
Springs and spring retainers of primary
drive assy. Worn
Noise with clutch engaged - ball bearing of
the pressure plate worn
Noise seem to come from the gearbox:
Tooth anks of the gearbox gears worn
Ball bearing of gearbox shafts and/or needle
bearings of gears worn
Replace piston rings broken or ring grooves
Replace crankshaft and/or conrod bearings
and /or replace crankshaft and conrods
Replace balancing swing arm with balancing rod
Replace friction plates and /or clutch
drum
Replace primary drive assy.
Replace clutch drum, clutch hub or pres-
sure plate
Replace springs and spring retainers
Replace ball bearing
Check gears and gear shafts, replace if
necessary
Replace bearings
Manuale d'officina Ed. 11-2011
C.6
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
Trouble Possible causes Remedy
Fatigue of clutch springs Replace clutch springs
Clutch slips
Clutch disengages unsatisfactorily
Clutch "drags" at engagement
Gears do not engage or gears jump out at
start or at abrupt acceleration
Clutch plates worn or warped Replace clutch plates
Engine oil not according to specications Exchange engine oil
Engine oil not according to specications Exchange engine oil
Clutch plates warped Exchange clutch plates
Clutch plates stuck together Clean or exchange
Clutch plates worn or warped Replace clutch plates
Guide slots for friction plates in clutch drum
are worn
Guide slots for steel plates in clutch hub
are worn
Gearshifting action incomplete Always actuate gearshift lever till stop
Gearshift lever incorrectly adjusted Correct position of gearshift lever
Fastener of gearshift lever loose Tighten fastener
Gearshift lever bent Replace gearshift lever
Function of index lever or index spring
imperfect
Adjustment of gearshift pawl incorrect
Engagement teeth and/or windows of ge-
arbox gears badly worn
Gearshift forks are worn or bent Exchange gearshift forks
Replace clutch drum
Replace clutch hub
Check index lever and index spring and
exchange if necessary
Check and adjust pawl wich spring, exchange if necessary
Exchange gears
Gearbox gears are worn or damaged Exchange gearshift gearbox gears
Clutch does not disengage See "Clutch disengages unsatisfactorily"
Gears can be shifted only noisily Clutch does not disengage See "Clutch disengages unsatisfactorily"
Spark plugs overheated, burnt or dirty
Generator does not charge or chargs
incorrectly
Spark plugs not according to specications
Spark plugs loose Tighten spark plugs
Intake socket not tight or leaking
Fuel supply system defective Check and replace if necessary
Battery faulty, loose or corroded connections
Rectier regluator defective Replace rectier regluator
Break in current, short circuit or earthing of
stator windings
Break in cables or short circuit, connections
loose
Replace spark plug
Tighten intake socket or exchange if necessary
Check/replace battery and check connections
Replace stator
Check and replace if necessary
C.7
Manuale d'officina Ed. 11-2011
TROUBLESHOOTING
NUDA 900 2012/2013 - NUDA 900 R 2012/2013
CHASSIS
Trouble Cause Remedy
Insufcient tyre pressure Inate
Handlebar turns hard
Handlebar vibration
Damping is too hard
Damping is too soft
(Front / rear) wheel shakes
Rear suspension is noisy
Poor braking (front and rear)
Bearing adjuster ring nut or steering stem
nut overtightened
Bent steering stem Replace bottom yoke
Worn or seized steering bearings Replace
Bent fork legs Replace
Bent front wheel axle Replace
Warped chassis Replace
Bent front wheel rim Replace
Worn front wheel bearings Replace
Improperly balanced wheel Balance
Too much oil in fork legs Remove excess oil
Fork oil viscosity too high Change
Overinated tyres Deate
Improperly set rear shock absorber Adjust
Insufcient 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
Bent wheel rim Replace
Worn wheel hub bearings Replace
Wheel axle nut loose Tighten
Worn rear swinging arm bearings Replace
Improperly balanced wheel Balance
Worn shock absorber ball joints Replace
Shock absorber faulty Replace
Air in brake system Bleed
Insufcient uid in tank Top up
Worn brake pad and/or disc Replace
Damaged disc Replace
Adjust
Manuale d'officina Ed. 11-2011
C.8
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