Husqvarna NUDA 900 R (2012), NUDA 900 (2012), NUDA 900 (2013), NUDA 900 R (2013) Workshop Manual

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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 modiced drawing in H12123. 02 08/11/2012 M.21 H10942 modiced 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 reect on-going product development. Illustrations in the manual may differ from

actual components. No reproduction in full or in part without written authorisation.

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

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 superuous. 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 signicance are identied 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 specic 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

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 specied, data and specications apply to all models.

a.3

Workshop Manual Ed. 11-2011

IMPORTANT NOTICES

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

Section

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 inammable 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

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 inammable 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 specied, 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 specied 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 specied.

- Clean thoroughly the removed components before retting 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 specied, ret 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.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

 cartridgelter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

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

.....................................................twinoatingdiscø12,6in.(ø320mm)

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 ...............................xeddiscø10,43in.(ø265mm)andoatingcalliper

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

Oilandoillter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

......................................................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

Brakeuid...........................................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;

- Electroniccontrolunitonthefrontpartinfrontofthelterbox;

- 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;

- Turningindicatorasher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 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

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.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

SERVICE COUPON

EVERY

10.000 Km

SERVICE COUPON

EVERY

20.000 Km

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)

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

Workshop Manual Ed. 11-2011

SERVICE COUPON

EVERY

40.000 Km

B.3

TROUBLESHOOTING

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

Section

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 specications

or defective Spark plugs fouled or wet Clean or exchange

Battery nearly discharged, starting rpm too low

Fuel supply inadequate

Valve clearance below specication

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-

cication

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-

cication

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-

cication

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 insufcient performance

Valve clearance below specication

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 specications

or defective Valve clearance not according specica-

tion Valve timing incorrect Adjust position of camshaft gears

Ignition coil supplies insufcient 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 specications 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 specications

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 Rell 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 specied octane number (min.

ROZ 95) Replace spark plug Check / replace intake socket and intake

system Check / replace crank position trigger and

ECU Rell 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 Rell 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-

cication

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 insufcient 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 specications Exchange engine oil Engine oil not according to specications 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 specications

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

Rectier regluator defective Replace rectier 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

Insufcient tyre pressure Inate

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

Overinated tyres Deate

Improperly set rear shock absorber Adjust Insufcient 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 Insufcient uid in tank Top up Worn brake pad and/or disc Replace Damaged disc Replace

Adjust

Manuale d'officina Ed. 11-2011

C.8

TROUBLESHOOTING

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

ELECTRICAL SYSTEM (see also Section M)

Trouble Cause Remedy

Dirty air lter Clean

Spark plug fouls easily

Spark plug electrodes overheat

Generator does not charge or is not providing enough charge

Generator overcharges battery Voltage regulator faulty Replace

Battery does not hold charge

Starter motor does not start or slips

Worn piston rings Replace Worn piston or cylinder liner Replace Spark plug electrode gap too close Adjust Wrong heat rating Replace with recommended spark plug Cables running to voltage regulator im-

properly connected or shorted Voltage regulator faulty Replace Faulty generator Replace

Battery terminals dirty Clean Faulty generator Replace Faulty battery Replace Battery is at Charge Control on R.H. switch faulty Replace Starter relay faulty Replace Starter motor faulty Repair or replace Worn starter gears Replace Worn or damaged freewheel rollers Replace freewheel Ignition key not recognised Check control unit key immobiliser

Connect correctly or replace

C.9

Manuale d'officina Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Section

D.1

Workshop Manual Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Sommario

Saddle removal.............................................................................................D.3

Central cover removal ..................................................................................D.4

Side panel removal .......................................................................................D.5

Throttle cable adjustment .............................................................................D.5

Throttle control..............................................................................................D.6

Front brake control .......................................................................................D.6

Position adjustment ......................................................................................D.6

Front brake lever adjustment and uid level check ......................................D.7

Clutch control................................................................................................D.8

Clutch control lever distance adjustment ......................................................D.8

Clutch free play adjustment ..........................................................................D.9

Rear brake pedal free play adjustment.........................................................D.9

Rear brake uid level check

Oil level check ............................................................................................D.10

Engine oil replacement and cartridge lter replacement ............................D.11

Coolant level check

Coolant replacement ..................................................................................D.12

Air lter check

Chain adjustment .......................................................................................D.16

Lubricating the chain ..................................................................................D.17

Suspension Suspension settings summary tables Rear shock absorber

Spring preload adjustment NUDA 900........................................................D.21

Spring preload adjustment NUDA 900 R

Adjustment shock absorber length NUDA 900 R........................................D.23

Shock absorber hydraulic damping adjustment..........................................D.24

Fork adjustment NUDA 900 Fork adjustment NUDA 900 R

Fuel supply hose inspection and replacement ...........................................D.26

Exhaust system check Idle speed adjustment

....................................................................................D.12

.............................................................................................D.15

................................................................................................D.18

.......................................................................D.10

.........................................................D.18

..................................................................................D.20

....................................................D.22

.......................................................................D.25

....................................................................D.25

................................................................................D.27

Workshop Manual Ed. 11-2011

D.2

SETTINGS AND ADJUSTMENTS

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

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.

H10662

H10663

D.3

Workshop Manual Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Central cover removal

- Insert the key in the lock and remove the cap (1).

H10664

- Remove the screw (2) under the cap.

H10665

- Loosen the ve 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.

H10666

Workshop Manual Ed. 11-2011

H10667

H10668

D.4

SETTINGS AND ADJUSTMENTS

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

Side panel removal

H10669

- Remove the saddle as described in the relevant paragraph.

- Loosen the ve screws (1) and remove the right-hand side (2).

- Perform the same procedures for the removal of the left-hand side.

During the reassembly, tighten the screws with the respective

bushings, and position the M6 screw (1a) in the 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 lter 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 in.);

- tighten check nut (2).

- reassemble all parts, in the reverse order compared to disassembly.

2 mm

(0,08 in.)

Operation with damaged throttle cable could result in an unsafe

riding condition.

H10670

When throttle control cables (4) are replaced, adjust new cables as previously explained.

H10906

D.5

Workshop Manual Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Throttle control

The throttle twistgrip is located on the right-hand side of the handlebar:

Throttle position adjustment

The position of the control on the handlebar can be adjusted by loosening the two retaining screws (2).

Do not forget to tighten the screws (2) after adjusting.

H10672

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

H10673

A stop switch, during the braking action, causes the stop light on the tail light to come on.

Workshop Manual Ed. 11-2011

Do not forget to tighten the screws (2) after adjusting.

D.6

SETTINGS AND ADJUSTMENTS

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

Front brake lever adjustment and uid level check

The lever (1) can be set to ve different positions according to the size of the

rider’s hand. To decrease the lever (1) distance from the handgrip, turn the

MAX

adjuster screw (2) COUNTER CLOCKWISE “A”. Fluid level inside master cylinder tank shall never be below the min. level (3) indicated on the transparent tank (4).

A decrease of the uid level will let air into the system, hence an extension of

the lever stroke.

MIN

H10676

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 uid onto any painted surface or lens (for example

lights lens).

Do not mix two brands of uid. Completely change the brake uid

in the brake system if you wish to switch to another uid brand.

Brake uid may cause irritation. Avoid contact with skin or eyes.

In case of contact, ush thoroughly with water and call a doctor if your eyes were exposed.

H10674

H10675

Workshop Manual Ed. 11-2011

D.7

SETTINGS AND ADJUSTMENTS

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

Clutch control

The clutch control lever (1) is located on the left-hand side of the handlebar.

H10677

Position adjustment

The position of the clutch control on the handlebar can be adjusted by loosening the retaining screws (2).

After adjustment, turn the handlebar as far as possible 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.

Workshop Manual Ed. 11-2011

H10678

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 explained thereafter.

- To move the lever away from the handgrip, turn the adjuster screw (2) clock-

wise (A);

- T o move the lever closer to the handgrip, turn the adjuster screw (2) counter-

clockwise (B).

Release the lever.

H10679

D.8

SETTINGS AND ADJUSTMENTS

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

Clutch free play adjustment

Free play (A) must be 5 -10 mm (0.196 - 0.39 in). It can be adjusted by turning and adjuster screw on the clutch cover.

- Loosen the check nut (1) and adjust play by turning the threaded pin (2); -

after adjustment tighten the nut (1).

H10680

H10681

Rear brake pedal free play adjustment

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);

H10682

- 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 BRAKE INEFFECTIVENESS.

If the brake pedal 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).

C: to increase clearance D: to decrease clearance

H10683

Workshop Manual Ed. 11-2011

D.9

MAX

SETTINGS AND ADJUSTMENTS

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

Rear brake uid level check

The uid level in the master cylinder tank shall never be below the minimum level

(1) shown on the transparent reservoir (2).

MIN

A decrease in the uid level will let air into the system and increase the lever

stroke.

If the brake pedal feels mushy when pulled, there may be air in the

brake lines or the brake may be defective.

Do not spill brake uid onto any painted surface or light lens.

H10684

MAX

MIN

Do not mix two brands of uid. Completely change the brake uid

in the brake system if you wish to switch to another uid brand.

Brake uid may cause irritation. Avoid contact with skin or eyes.

In case of contact, ush 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 ground, wait a few minutes for

the oil to reach the sump.

- Check the level as follows:

- Undo the cap (1) with the dipstick (2) and remove it from the engine.

- Clean the dipstick (2) with a cloth.

- Place the dipstick (2) in the hole (3) without screwing the cap on.

- Remove the dipstick (2) from the hole (3) and check that the level is

between the two MIN and MAX marks.

- To top up, pour oil into the hole (3); for the type of oil, see the section “Techni-

cal data”.

H10685

Workshop Manual Ed. 11-2011

D.10

SETTINGS AND ADJUSTMENTS

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

Engine oil replacement and cartridge lter replacement

Be careful not to touch hot engine oil.

H10686

Drain the oil with WARM ENGINE; proceed as follows:

- Place the motorcycle on the side stand;

- remove oil ller cap (1);

- place a pan under the engine drainage plug;

- remove oil drainage plug (2);

- drain the exhausted oil, and clean magnet on plug (2);

- using a suitable tool, unscrew the cartridge lter (3) and remove it;

- replace the lter (3) with a new one and clean the contact surfaces between

the lter 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 into the oil hole (4);

- ret the oil drainage plug (1).

H10687

Switch on the engine for a short period of time to allow the oil to

reach all parts of the engine and check the level as described in the relevant section.

H10688

D.11

Workshop Manual Ed. 11-2011

MAX

MIN

SETTINGS AND ADJUSTMENTS

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

Coolant level check

When the engine is cold, check that the coolant level is between the two MIN and MAX marks on the expansion tank (1) on the right side of the vehicle. If topping up is necessary, do the following:

- Remove the saddle and side panels, as described in the relevant sections.

H10689

Do not remove the radiator cap (2) since all the liquid in the expan-

sion tank (1) will ow out.

- Remove the cap (3) and add the uid needed to restore the level to the ex-

pansion tank (1).

(for the type of liquid to use, see the section “Technical data”).

Difculties may arise in eliminating coolant from painted surfaces.

If this occurs, wash off with water.

H10907

Coolant replacement

- Put the motorbike in a vertical position.

- Remove the saddle, the right-hand side as outlined in the relevant sections.

- Put a 2 Lt bucket under the engine.

Workshop Manual Ed. 11-2011

- Loosen the screw (1) on the engine head and let the coolant drain.

H10691

D.12

SETTINGS AND ADJUSTMENTS

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

- Loosen the screw (2) of the lower pipe (3) that connects the radiator (4) to

the exchanger (5).

H10692

- 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.

H10693

- Put the motorbike on the side stand.

H10694

H10695

Workshop Manual Ed. 11-2011

D.13

SETTINGS AND ADJUSTMENTS

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

MAX

MIN

H10696

- Remove the radiator cap (9).

- Loosen the coolant bleed screw (10) on the water pump cover and at the same time continue to pour liquid in the radiator until it comes out of the hole of the bleed valve, then tighten again the bleed valve (10).

- Top up with coolant until the maximum level of the radiator (cap upper border).

- Ret 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 pressure discharge, then remove the cap.

- Top up with coolant until the maximum level of the radiator (cap upper border).

- Restart the engine and repeat the procedures until the level of the radiator liquid reaches the maximum level.

- Ret the radiator cap (9).

- Remove the expansion tank (12) cap (11) and pour in liquid until the level is between the minimum and the maximum level.

H10697

- Ret the cap (11).

Workshop Manual Ed. 11-2011

D.14

SETTINGS AND ADJUSTMENTS

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

Air lter check

- Remove the upper cover as described in the relevant section.

- Disconnect connector (1) of the air temperature sensor.

- Unscrew the two screws (2) that fasten the side panels at the front.

H10698

- Unscrew the screws (3) on the lter cover (4) and remove it.

H10699

- Clean the area around the lter (5) before removing it.

H10700

- Remove the lter (5), check that it is not clogged and replace if necessary.

Before retting the lter, check that the contact surfaces between

the lter, the lter box and the cover are completely clean.

H10701

Workshop Manual Ed. 11-2011

D.15

SETTINGS AND ADJUSTMENTS

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

Chain adjustment

Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear. If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or too tight), it could jump out of the sprocket or break.

Check that distance "A" between the chain (1) and the bottom part of the slider (2) measures 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).

H10702

- 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 tension and check on both sides that the wheel centring sliders (6) are in the same position as the mark-

H10703

ings in the chain tensioner slider seats on the swinging arms;

- once adjusted, tighten the check nuts (4) and the wheel axle nut (3).

After adjusting, always check that distance "A" is 25 ÷ 30 mm (0.984 ÷ 1.181

in).

Workshop Manual Ed. 11-2011

H10704

D.16

SETTINGS AND ADJUSTMENTS

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

Lubricating the chain

Lubricate the chain following these instructions.

Never use grease to lubricate the chain. Grease 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 ammable solvents.

- After washing the chain using special detergent, dry it and lubricate with suitable spray grease.

The chain lubricant must NOT come into contact with the tyres or

the rear brake disc.

D.17

Workshop Manual Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Suspension

The vehicle leaves the factory with standard settings for the front and rear suspension that meet most requirements. On "NUDA 900" motorcycles, the front fork cannot be adjusted whereas the hydraulic rebound on the rear shock absorber can be

adjusted. On "NUDA 900 R" motorcycles the suspension can be adjusted according to the type of use and load.

The motorcycle suspension can be adjusted for track use only (Motard version).

The Motard version suspension has been designed exclusively for track use.

Road use is not recommended. NOTE: Before making any change and afterwards, if the adjustment is not satisfactory, always start from the standard

suspension setting and increase or decrease the adjusting clicks, one at a time.

The various adjustments must be made on the front fork and the rear shock absorber as described in the following

tables.

Suspension settings summary tables

SHOCK ABSORBER

Length of shock absorber "A" - - 380 mm

Shock absorber compression adjustment

Shock absorber rebound adjustment

Shock absorber spring constant "K"

FORK

Compression adjustment - - 6 clicks 3 clicks 6 clicks Rebound adjustment - - 10 clicks 10 clicks 10 clicks Fork spring constant "K" 6,5 N/mm

Position of fork "A" 220 mm (8,66 in) 220 mm (8,66 in) 230 mm

Standard pre-load - - 5 turns

NUDA 900

- - 16 clicks 14 clicks 16 clicks

25 clicks 10 clicks 18 clicks 9 clicks 18 clicks

105 N/mm

NUDA 900

7,0 N/mm (RBND)

NUDA 900 with panniers and passenger

105 N/mm 100 N/mm 100 N/mm 100 N/mm

NUDA 900 with panniers and

passenger

6,5 N/mm 7,0 N/mm (RBND)

NUDA 900 R

(14,96 in)

NUDA 900 R

7,0 N/mm 7,0 N/mm

(9,05 in)

NUDA 900 R Motard

385 mm (15,15 in)

NUDA 900 R Motard

7,0 N/mm 7,0 N/mm

240 mm (9,45 in)

NUDA 900 R with panniers and passenger

380 mm (14,96 in)

NUDA 900 R with panniers and pas-

senger

7,0 N/mm 7,0 N/mm

230 mm (9,05 in)

Workshop Manual Ed. 11-2011

D.18

SETTINGS AND ADJUSTMENTS

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

NOTE: Fork springs and shock absorbers with varying degrees of stiffness

H10705

NOTE: Do not go beyond 385 mm.

are available above all for use with passenger and/or panniers.

“A” = 380 mm (NUDA 900)

“A” = 385 mm (NUDA 900 R Motard)

“A” = 380 mm (NUDA 900 R)

H10706

D.19

Workshop Manual Ed. 11-2011

“A” = 380 mm (NUDA 900)

“A” = 385 mm (NUDA 900 R Motard)

SETTINGS AND ADJUSTMENTS

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

Rear shock absorber

Depending on the installed rear shock absorber model, it is possible to perform different adjustments as reported in the following table:

“A” = 380 mm (NUDA 900 R)

H10706

SHOCK ABSORBER

Length of shock absorber "A" - - 380 mm

Shock absorber compression adjustment

Shock absorber rebound adjustment

Shock absorber spring constant "K"

NUDA 900

- - 16 clicks 14 clicks 16 clicks

25 clicks 10 clicks 18 clicks 9 clicks 18 clicks

105 N/mm

NUDA 900 with panniers and passenger

105 N/mm 100 N/mm 100 N/mm 100 N/mm

Besides the adjustments in the table, it is possible to adjust the spring preload as follows:

NUDA 900 R

(14,96 in)

NUDA 900 R Motard

385 mm (15,15 in)

NUDA 900 R with panniers and passenger

380 mm (14,96 in)

Workshop Manual Ed. 11-2011

D.20

SETTINGS AND ADJUSTMENTS

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

Spring preload adjustment NUDA 900

- Remove the 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; 7.38 ft-lb).

H10707

380 ± 1,5 mm (14,96 ± 0,06 in.)

111,2 mm (4,38 in.) 162,5 ± 1,5 mm (6,4 ± 0,06 in.)

Wheelbase.

A: B: Spring in its seat.

NUDA 900

H10959

D.21

Workshop Manual Ed. 11-2011

SETTINGS AND ADJUSTMENTS

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

Spring preload adjustment NUDA 900 R

Proceed as follows:

1. Clean the lock ring nut (1), the adjuster 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

rmly (tightening torque 10 Nm - 1 Kgm - 7.38 ft-lb).

H10908

Be careful not to touch hot exhaust pipe while adjusting the shock

absorber.

NUDA 900 R

181 mm (7,13 in.)

380 ± 1,5 mm

14,96 ± 0,06 in.

H10960

Workshop Manual Ed. 11-2011

A: Spring in its seat (free length 190 mm / 7.48 in.). B: Wheelbase.

D.22

SETTINGS AND ADJUSTMENTS

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

Adjustment shock absorber length NUDA 900 R

- Remove the fuel tank as described in the relevant paragraph.

H10916

- Loosen the upper pin (1) that fastens the 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 not exceed the 385 mm length and do not exceed for any reason

the safety slot (4) on the threaded leg of the terminal (5).

H10917

NUDA 900 R

380 ÷ 385 mm

14,96 ÷ 15,16 in.

H10915

Workshop Manual Ed. 11-2011

D.23

SETTINGS AND ADJUSTMENTS

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

Shock absorber hydraulic damping adjustment

Nuda 900 The shock absorber can be adjusted in the rebound hydraulic damping.

B) REBOUND - Standard setting: Adjuster 1:

- 25 clicks (± 2 clicks)

H10713

T o reset the standard setting, turn lower adjuster (1) clockwise until reaching fully

closed position. Then turn it back the number of clicks specied above.

In order to obtain a 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:

H10715

- 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 (3) clockwise until reaching fully closed position. Then turn it back

the number of clicks specied above.

If you want to work on the adjuster screw (3), remove the right-hand panel. Turn the adjuster screw clockwise to increase compression damping or counterclockwise to decrease it.

Workshop Manual Ed. 11-2011

H10714

D.24

SETTINGS AND ADJUSTMENTS

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

Fork adjustment NUDA 900

On the fork installed on this motorbike version, it is not possible to perform any type of adjustment.

Fork adjustment NUDA 900 R

a) COMPRESSION (LOWER ADJUSTER) Standard setting: 6 clicks 900 R 3 clicks 900 R Motard

To reset standard calibration, turn adjuster screw (A) clockwise to reach the

fully closed position; then turn it back the number of clicks specified above.

Turn the adjuster screw clockwise to increase compression damping or counterclockwise to decrease it.

H10716

b) REBOUND (TOP ADJUSTER)

Standard setting: 10 clicks 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 counterclockwise to decrease it.

Never force the adjusting screws beyond the maximum open and

closed positions.

H10717

c) PRELOAD ADJUSTMENT To adjust, turn the central nut (C) on the cap. Turn the nut clockwise to increase the spring preload and counterclockwise to decrease it. If the default setting is restored, completely loosen nut (C) and then retighten it by turning it 5 turns clockwise.

FORK

Compression adjustment 6 clicks 3 clicks 6 clicks Rebound adjustment 10 clicks 10 clicks 10 clicks Fork spring constant "K" 7,0 N/mm

NUDA 900 R

7,0 N/mm

NUDA 900 R Motard

7,0 N/mm 7,0 N/mm

NUDA 900 R with panniers and pas-

senger

7,0 N/mm 7,0 N/mm

Workshop Manual Ed. 11-2011

D.25

SETTINGS AND ADJUSTMENTS

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

Fuel supply hose inspection and replacement

Check fuel supply hose (1) conditions; if cracked, swollen, kinked, etc. it is nec-

essary to change it as follows:

- Remove 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).

H10918

- Cut the clamp (4).

- Remove the lter box as described in the relevant section.

H10719

- 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 this operation, make sure that you do not damage the hose

holder coupling on the throttle body.

Workshop Manual Ed. 11-2011

H10720

D.26

SETTINGS AND ADJUSTMENTS

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

Exhaust system check

Perform a visual inspection of the exhaust system rst, in order to identify possible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.

Subsequently, inspect the single components by disassembling the exhaust system.

Moreover, check the tightening of the anges nuts (1) that fasten the manifold

to the cylinder head and of the fastening clamp (2) of the silencer to the manifold, as well as the tightening of the screw (3) that retains the silencer to its support.

The damaged or broken parts must be replaced.

H10919

H10920

H10921

H10922

Idle speed adjustment

The idle speed is pre-set by the control unit (1250 rev/min.) and the stepper motor ensures that this value is preserved. No manual adjustment is possible, nor any adjustment through the diagnostic tool.

Workshop Manual Ed. 11-2011

D.27

GENERAL PROCEDURES

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

Section

E.1

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Sommario

Stand removal / replacement........................................................................E.3

Stand foot replacement ................................................................................E.4

Saddle removal.............................................................................................E.5

Air-Box cover removal Side panels removal

Number plate holder removal .......................................................................E.7

Tail light removal ...........................................................................................E.9

Rear turning indicator removal

Tail removal ................................................................................................E.13

Front fairing removal...................................................................................E.14

Front turning indicator removal

Combined dashboard removal ...................................................................E.16

Front mudguard removal

Front mudguard n removal .......................................................................E.18

Battery removal

Reservoir removal ......................................................................................E.20

Fuel pump removal .....................................................................................E.22

Fuel pump inspection

Filter box removal .......................................................................................E.24

Throttle body removal

Exhaust system removal ............................................................................E.27

Exhaust system removal ............................................................................E.28

Lambda sensor removal .............................................................................E.30

Coil / Stick-Coil removal and spark plug test Horn removal

Radiator removal ........................................................................................E.32

Electric fan removal ....................................................................................E.34

Gearbox lever removal ...............................................................................E.34

Battery housing removal

Engine removal...........................................................................................E.37

Engine reassembly

..............................................................................................E.32

..................................................................................E.6

.....................................................................................E.7

...................................................................E.10

...................................................................E.15

............................................................................E.17

..........................................................................................E.19

.................................................................................E.23

.................................................................................E.26

..............................................E.31

.............................................................................E.35

.....................................................................................E.40

Workshop Manual Ed. 11-2011

E.2

GENERAL PROCEDURES

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

Stand removal / replacement

H10722

- Loosen the nut (1) and remove the rotary type switch (2).

H10723

- 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".

H10909

H10725

E.3

H10727

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Stand foot replacement

- Loosen the screw (7) and replace the foot (8) by reinstalling it exactly as the

gure shows.

H10726

H10728

Workshop Manual Ed. 11-2011

E.4

GENERAL PROCEDURES

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

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.

H10662

H10663

E.5

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Air-Box cover removal

- Insert the key in the lock and remove the cap (1).

H10664

- Remove the screw (2) under the cap.

H10665

- Loosen the ve 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.

H10666

Workshop Manual Ed. 11-2011

H10667

H10668

E.6

GENERAL PROCEDURES

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

Side panels removal

- Remove the saddle as described in the relevant paragraph.

- Loosen the ve screws (1) and remove the right-hand side (2).

- Perform the same 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.

H10669

Number plate holder removal

- Remove the saddle as described in the relevant paragraph.

- Disconnect the two connectors (1) and (2) of the rear harness.

H10729

- Loosen the two screws (3) that fasten the number holder (4) to the chassis.

H10730

- Remove the saddle fastening pin (5) using a rubber hammer (during the reassembly, replace the plastic washer (6)).

H10731

Workshop Manual Ed. 11-2011

E.7

GENERAL PROCEDURES

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

- Remove the two upper screws (7).

H10732

H10733

- Tilt the number plate holder (4) to the right and to the left, and remove it.

Workshop Manual Ed. 11-2011

E.8

GENERAL PROCEDURES

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

Tail light removal

- Remove the number plate holder as described in the relevant paragraph.

- Remove the O-ring (1) that fasten the cables.

H10734

- Loosen the two screws (2) with the related bushings and remove the tail light

(3).

H10735

H10736

E.9

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Rear turning indicator removal

- 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).

H10737

- 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.

Workshop Manual Ed. 11-2011

H10739

H10738

E.10

GENERAL PROCEDURES

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

- Loosen the four self-tapping screws (4).

- Loosen the two screws (5) that retain the turning indicators (6).

H10740

- Remove the lower cover (7).

H10741

- Disconnect the two connectors (8) and (9), and remove the two turning indicators (6).

H10742

Workshop Manual Ed. 11-2011

E.11

GENERAL PROCEDURES

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

- In case of replacement of the harness (10), cut the clamp (11), disconnect the number plate bulb holder (12), replace the harness (10) and reinstall it exactly in the same position by fastening it with the clamp (1 1) and passing it behind the tab (13).

H10743

H10745

H10744

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 harness.

Workshop Manual Ed. 11-2011

E.12

GENERAL PROCEDURES

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

H10746

Tail removal

- Remove the saddle, the sides and the number plate holder as described in the relevant paragraphs.

- Loosen the ve screws (1) and remove the tail (2) slipping it off towards the

rear part.

H10747

H10748

E.13

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Front fairing removal

- Loosen the two screws (1) and remove the spoiler (2).

H10749

H10750

Workshop Manual Ed. 11-2011

E.14

GENERAL PROCEDURES

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

Front turning indicator removal

- Remove the front fairing as described in the relevant paragraph.

- Disconnect the connector (1) of the left-hand indicator and the connector (2) of the right-hand indicator.

H10751

- Loosen the screws (3) and fully remove the indicators (4).

H10752

H10754

H10753

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 the bike harness.

Workshop Manual Ed. 11-2011

E.15

GENERAL PROCEDURES

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

Combined dashboard removal

- Remove the front fairing as described in the relevant paragraph.

H10755

- 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.

H10756

H10757

Workshop Manual Ed. 11-2011

E.16

GENERAL PROCEDURES

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

Front mudguard removal

- Loosen the six screws (1) that fasten the mudguard (2) to the fork making

H10758

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).

H10759

H10760

Workshop Manual Ed. 11-2011

E.17

GENERAL PROCEDURES

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

Front mudguard n removal

- Loosen the screw (1) and remove the n (2); during the reassembly, t the

H10761

tab (3) in the special seat (4), then tighten again the screw (1).

H10762

Workshop Manual Ed. 11-2011

E.18

GENERAL PROCEDURES

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

Battery removal

H10763

- Make sure that the ignition switch has been turned to OFF and that the key has been removed;

– loosen the three screws (1);

- remove the cover (2);

- rst remove the BLACK or BLUE negative cable, then the RED positive cable (when reassembling, rst connect the RED positive cable, then the BLACK or BLUE negative cable);

H10764

H10765

- 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 contact between the

poles of the battery and the metallic parts of the vehicle (e.g. chassis) in order to prevent the risk of short-circuits.

E.19

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Reservoir removal

- Disassemble the saddle, the sides, the 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 tting (3).

A small quantity of fuel can come out of the pipe.

H10766

- Cut the clamp (4) that retains the fuel pipe (5).

- Move the fuel pipe (5).

H10767

- Remove the reservoir breather hose (6) from the cap ange (7).

Workshop Manual Ed. 11-2011

H10768

- Loosen the reservoir centring screw (8).

H10769

E.20

GENERAL PROCEDURES

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

- 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 ange (7).

H10910

During the reassembly, replace the screws (9).

H10771

H10772

H10773

H10774

Workshop Manual Ed. 11-2011

E.21

GENERAL PROCEDURES

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

Fuel pump removal

- Disassemble the saddle as described in the relevant paragraph.

- Disconnect the connector (1).

- Disconnect the fuel pipe (2) by loosening the two screws; collect the fuel that could come out.

H10775

- Use a suitable tool to loosen the ring nut (3) and remove the reservoir pump

(4).

H10776

- 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.

H10778

- During the reassembly of the pump the reference tab (6) on the pump (4) should coincide with the seat (7) in the reservoir ring nut.

- Reinstall the ring nut (3) and tighten it with a suitable tool.

Workshop Manual Ed. 11-2011

H10777

E.22

GENERAL PROCEDURES

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

Fuel pump inspection

Remove the pump as described in the relevant paragraph.

- Connect 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.

H10962

HYDRAULIC DIAGRAM

REGULATOR

FINE FILTER

PRE-FILTER

OUT

PUMP

FUEL

ELECTRIC DIAGRAM

FUEL SYSTEM

GROUND

SIGNAL

GROUND

H10963

GROUND

FILTER

H10964

E.23

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Filter box removal

- Remove the fuel tank as described in the relevant paragraph.

- Disconnect and remove the connector (1) of the air temperature.

H10779

- Disconnect the connector (2) of the idle air actuator (Stepper motor).

H10923

- Remove the two small tubes (3) of the idle air actuator (Stepper motor) on the throttle body.

H10924

- Loosen the two nuts (4) that fasten the chassis.

Workshop Manual Ed. 11-2011

H10782

E.24

GENERAL PROCEDURES

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

- Loosen the two front screws (5).

H10783

- Lift the lter box (6).

H10784

- Open the clamp (7) and remove the Blow-By pipe (8); remove the lter box

(6).

During the reassembly , the throttle control cable (9) must pass over

the pipe (8).

H10785

H10786

Workshop Manual Ed. 11-2011

E.25

GENERAL PROCEDURES

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

Throttle body removal

- Remove the reservoir and the lter box as described in the relevant paragraphs.

- 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).

H10787

- Remove the throttle body (1).

H10788

H10789

Workshop Manual Ed. 11-2011

E.26

GENERAL PROCEDURES

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

Exhaust system removal

H10925

Key

1. Silencer

2. Clamp

3. Exhaust valve actuator starter motor

4. Lambda sensor

5. Manifold

6. Gasket

E.27

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Exhaust system removal

- Remove the radiator and the reservoir as described in the relevant paragraphs.

- Remove the protection (1) by loosening the screws (2).

H10793

- Loosen the nuts (3) and disconnect the cables (4) that control the exhaust valve.

H10794

- Loosen the screw (5) of the clamp (6) that fasten the silencer to the exhaust pipe (7).

Workshop Manual Ed. 11-2011

H10795

H10796

- Loosen the screw (8) and remove the silencer (6).

H10797

E.28

GENERAL PROCEDURES

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

- Loosen the nuts (9) of the exhaust manifold (10).

H10798

- Disconnect the connector (11) of the Lambda sensor.

H10799

- Cut the clamp (12).

- Loosen the central screw (13) of the manifold support (10).

- Remove the manifold (10).

H10800

H10801

H10802

Workshop Manual Ed. 11-2011

E.29

GENERAL PROCEDURES

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

H10803

- During the reassembly, check the seals (14) for wear, replace if damaged.

H10804

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.

Workshop Manual Ed. 11-2011

H10805

H10806

H10807

E.30

GENERAL PROCEDURES

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

Coil / Stick-Coil removal and spark plug test

Spark plug electrodes gap shall be 0.8 ÷ 0.9 mm (0.031

A wider gap may cause difculties in starting the engine and overload the coil. A gap that is too narrow may cause difculties when accelerating, when idling

or poor performance at low speed. Clean off any dirt around spark plug base before removing the spark plug. It is very useful to examine the state of the spark plug just 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 insulator tip is vitried (glazed),

white or grey in colour.

÷ 0.035 in).

0,8 ÷ 0,9 mm (0,031 ÷ 0,035 in)

To remove spark plug, proceed as follows:

- Remove the reservoir and the lter box as described in the relevant paragraphs.

- Disconnect the connector (1) from the coil / Stick-Coil (2).

- Lift the coil / Stick-Coil (2) to remove it from the cylinder head.

H10808

- Loosen the spark plug with a suitable key to remove it from the cylinder head.

H10809

Workshop Manual Ed. 11-2011

E.31

GENERAL PROCEDURES

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

Horn removal

- Unscrew the screw (1).

- Disconnect the connector and remove the horn (2).

H10810

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.

H10811

- Remove the two pipes (2) and (3) from the radiator.

H10812

- Open the clamp (4) and remove the pipe (5) that connects the expansion tank to the radiator.

Workshop Manual Ed. 11-2011

H10813

E.32

GENERAL PROCEDURES

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

- Loosen the screw (6).

H10814

- Cut the fan harness retaining clamp (7).

H10815

- Disconnect the connector (8) of the fan.

H10816

- Remove the radiator (9) from the right-hand side of the bike, by removing it from the special clips.

H10817

Workshop Manual Ed. 11-2011

E.33

GENERAL PROCEDURES

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

- During the reassembly, make sure that the pins (10) and (11) t in the support

(12) and (13) respectively.

H10818

H10819

H10820

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).

Workshop Manual Ed. 11-2011

H10821

E.34

GENERAL PROCEDURES

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

Battery housing removal

- Remove the battery, the reservoir , 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.

H10822

- Remove the connectors (2), (3), and (4) from the battery housing.

- Cut the clamps (5) that retain the harness.

H10823

- Disconnect the connector (6) and detach the solenoid starter (7) from the support bracket.

H10824

Workshop Manual Ed. 11-2011

E.35

GENERAL PROCEDURES

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

- 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.

H10825

During the reassembly, position again correctly the bushings (1 1).

- Keep the shock absorber lifted and turn the battery housing clockwise, then

remove it from the rear side.

H10826

Workshop Manual Ed. 11-2011

H10827

H10828

E.36

GENERAL PROCEDURES

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

Engine removal

Remove in a sequence the following components, as described in the relevant paragraphs/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).

H10829

- Remove the la retaining pin (5) and detach the master cylinder (6) from the lever (7).

H10830

- Remove the left-hand footrest (8) with the support, by loosening the screws (9).

H10831

During the reassembly, replace the screws (9).

Workshop Manual Ed. 11-2011

E.37

GENERAL PROCEDURES

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

- Loosen the screw (10) on the left side and the screw (11) on the right side keeping the spacer (12).

H10832

H10833

- Disconnect from the engine the cable (13) of the clutch.

H10834

Workshop Manual Ed. 11-2011

E.38

GENERAL PROCEDURES

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

- Remove the harness (14) from the bike by cutting the retaining clamps.

H10835

- 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.

H10836

E.39

Workshop Manual Ed. 11-2011

GENERAL PROCEDURES

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

Engine reassembly

H10837

- 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).

H10838

H10839

Workshop Manual Ed. 11-2011

H10840

E.40

Husqvarna NUDA 900 R (2012), NUDA 900 (2012), NUDA 900 (2013), NUDA 900 R (2013) Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Workshop Manual Ed. 11-2011

Table of Contents

IMPORTANT NOTICES

GENERAL INFORMATION

MAINTENANCE

TROUBLESHOOTING

SETTINGS AND ADJUSTMENTS

GENERAL PROCEDURES