Husqvarna SMS 125 2011 Manual de instrucciones

CR 125 2011

WR 125 2011

Workshop Manual Ed. 06-2011

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.

1st edition (06-2011)

a.1

simbolo

CR 125 2011 - WR 125 2011

H06663

Workshop Manual Ed. 06-2011

FOREWORD, TABLE OF CONTENTS

1st edition (06-2011)

Printed in Italy

MODELS COVERED (from serial number onwards)

HUSQVARNA MOTORCYCLES S.R.L.

BMW Group

Technical Service

Via Nino Bixio, 8

21024

(Varese) - Italy

tel. ++39 0332 75.61.11

tel. ++39 0332 756 558

www.husqvarna-motorcycles.com

Workshop Manual

1. Chassis serial number

TE 250 - 310 2011 I.E.

CR 125 2011

WR 125 2011

CR 125: ZKH4H00AABV050001

WR 125: ZKH4H00AABV000001

a.2

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CR 125 2011 - WR 125 2011

FOREWORD, TABLE OF CONTENTS

Workshop Manual Ed. 06-2011

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 comple-

ment to operator training and operators should become thoroughly familiar with it.

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.

Recommended shop practices

1 Always replace gaskets, sealing rings and split pins with new ones.

2 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.

3 Always mark any parts or positions that might be confused upon assembly.

4 Use genuine HUSQVARNA parts and the recommended lubricant brands.

5 Use special tools where specied.

6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

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CR 125 2011 - WR 125 2011

Workshop Manual Ed. 06-2011

FOREWORD, TABLE OF CONTENTS

Table of Contents

Title Section

Foreword, Table of contents ................................................................................ a

Important notices ................................................................................................. b

General information.............................................................................................A

Maintenance........................................................................................................B

Troubleshooting.................................................................................................. C

Settings and adjustments ................................................................................... D

General procedures.............................................................................................E

Engine disassembly.............................................................................................F

Engine overhaul.................................................................................................. G

Engine assembly ................................................................................................ H

Front suspension .................................................................................................. I

Rear suspension.................................................................................................. J

Brakes ................................................................................................................. L

Electrical system................................................................................................. M

Engine cooling.................................................................................................... N

Special tools .......................................................................................................W

Tightening torque gures.....................................................................................X

Chassis and wheels.............................................................................................Y

NOTES

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

b.1

CR 125 2011 - WR 125 2011

Workshop Manual Ed. 06-2011

IMPORTANT NOTICES

Section

b.2

CR 125 2011 - WR 125 2011

H06664

CR 125

H06665

WR 125

IMPORTANT NOTICES

Workshop Manual Ed. 06-2011

CR models are RACING motorcycles and are warranted to be free from op-

erating defects; a scheduled maintenance chart for racing use is provided in

Section B.

WR models are for ROAD USE (DERATED); they are guaranteed exempt from

functional defects and covered with legal guarantee, as long as the STANDARD

CONFIGURATION IS MAINTAINED and the suggested maintenance table

shown in Section “B” is observed.

For WR models modied to RACING SPECIFICATIONS (FULL POWER

RATING), observe the scheduled maintenance chart for racing use provided

in Section B.

* This motorcycle has not been designed to travel over long distances with the

engine at top rpm, as in long-distance road or highway travel. Riding over

long distances at full throttle may result in severe engine damage.

IMPORTANT

VEHICLE CONFIGURATION as outlined below is a prerequisite for the war-

ranty to remain valid:

A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED;

B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER EN-

GINE

* 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 changing parts and for the labour necessary in order

to comply with the maintenance plan is charged to the Client. The warranty

becomes NULL AND VOID if the motorcycle is rented.

Notes

Left and right side is determined when seated on motorcycle.

Unless otherwise specied, data and instructions apply to all market variants.

A.1

CR 125 2011 - WR 125 2011

Workshop Manual Ed. 06-2011

GENERAL INFORMATION

Section

A.2

CR 125 2011 - WR 125 2011

GENERAL INFORMATION

Workshop Manual Ed. 06-2011

Engine ..........................................................................................................A.3

Starting .........................................................................................................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

Transmission ratio ........................................................................................A.4

SECONDARY DRIVE...................................................................................A.4

FINAL RATIOS .............................................................................................A.4

FRAME.........................................................................................................A.4

FRONT SUSPENSION.................................................................................A.4

REAR SUSPENSION...................................................................................A.4

FRONT BRAKE ............................................................................................A.4

REAR BRAKE ..............................................................................................A.4

RIMS.............................................................................................................A.4

Tires..............................................................................................................A.4

Cold tire pressure .......................................................................................A.5

Electrical components location.....................................................................A.5

Overall dimensions.......................................................................................A.6

Weight ..........................................................................................................A.6

Capacities.....................................................................................................A.7

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