Husqvarna SM 50 / 2011 Instruction manual

Workshop Manual
CR 50 / 2011
SM 50 / 2011
Ed. 01-09-2010

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 ma-
nual may differ from actual components. No reproduction in full or in part
without written authorisation.
1st edition (10-2009)

a.1
H02017
1
FOREWORD, TABLE OF CONTENTS
Ed. 01-09-2010
1st edition (09-2010)
Printed in Italy
MODELS COVERED (from serial number onwards)
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com
Workshop Manual
CR 50: ZKHCR5030BV000001
SM 50: ZKHSM5030BV000001
1. Chassis serial number
CR 50 / 2011
SM 50 / 2011

a.2
FOREWORD, TABLE OF CONTENTS
Ed. 01-09-2010
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.
IMPORTANT: Where not specied, reassembled components must be tightened to the proper torque as indicated
in the tables provided in Chapter "X".

a.3
FOREWORD, TABLE OF CONTENTS
Ed. 01-09-2010
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 .................................................................................................................F
Front Suspension ................................................................................................. I
Rear Suspension................................................................................................. J
Brakes ................................................................................................................. L
Electrical System ................................................................................................ M
Engine Cooling ................................................................................................... N
Special Tools ......................................................................................................W
Tightening Torque Figures ...................................................................................X
Chassis and Wheels............................................................................................Y
NOTES
Unless otherwise specied, data and specications apply to all models.

b.1
b
Ed. 01-09-2010
IMPORTANT NOTICES
Section

b.2
H02018
Ed. 01-09-2010
IMPORTANT NOTICES
1) CR models are RACING motorcycles, and are warranted to be free from
operating defects; a scheduled maintenance chart for racing use is provided
in Section B.
* 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.
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.

A.1
A
Ed. 01-09-2010
GENERAL INFORMATION
Section

A.2 Ed. 01-09-2010
GENERAL INFORMATION
Engine ..........................................................................................................A.3
Fuel system ..................................................................................................A.3
Lubrication....................................................................................................A.3
Cooling .........................................................................................................A.3
Ignition system..............................................................................................A.3
Starter ..........................................................................................................A.3
Drive and Transmission................................................................................A.3
Chassis.........................................................................................................A.3
Suspension...................................................................................................A.3
Brakes ..........................................................................................................A.3
Wheels..........................................................................................................A.4
Tyres.............................................................................................................A.4
Electrical components location.....................................................................A.4
Overall dimensions - Weight.........................................................................A.5
Capacities.....................................................................................................A.5

A.3Ed. 01-09-2010
GENERAL INFORMATION
Engine
Single cylinder, 2 stroke
Bore......................................................................................................39.5 mm
Stroke ......................................................................................................40 mm
Displacement..........................................................................................49 cm3.
Compression ratio ...................................................................................7.12:1
Fuel system
Carburettor type ...........................................................Dell'Orto.........PHBG 19
High speed jet.................................................................................................85
Low speed jet ................................................................................................65
Lubrication
Engine ................................................ 3% fuel-oil mixture during running-in and 2% after running-in.
Crankcase
Cooling
Liquid, with twin radiator
Ignition system
Spark plug type..........................................................................NGK BR8 ECM
Spark plug electrode gap........................................................................0.7 mm
Kick start
Drive and transmission
Drive pinion gear ........................................................................................ Z 10
Sprocket .................................................................................................... Z 43
Transmission ratio ........................................................................................4.3
Chassis
Single frame, in steel tubes with rectangular and circular section; rear chassis in steel squared sectioned tubes.
Suspension
Front
Type............................hydraulic fork with advanced stanchion; tubes ø 32 mm
Travel.....................................................................................................185 mm
Rear
Type...................................... progressive with hydraulic single shock absorber
(spring preload adjustment)
Wheel travel...........................................................................................200 mm
Brakes
Front
Type...................................................................................xed disc Ø 260 mm
with hydraulic control.
Rear
Type...................................................................................xed disc Ø 260 mm
with hydraulic control.

A.4
995 mm (39,17 inch)
1400 mm (55,11 inch)
655 mm (25,79 inch)
H06247
192 mm (7,55 inch)
213 mm (8,38 inch)
680 mm (26,77 inch)
250 mm
(9,84 inch)
880 mm (34,65 inch)
Ed. 01-09-2010
GENERAL INFORMATION
Wheels
Rims
CR
Front ..................................................................................in light alloy: 1.5x12”
Rear...................................................................................in light alloy: 1.6x10”
SM
Front ..................................................................................in light alloy: 1.5x10"
Rear...................................................................................in light alloy: 1.5x10"
Tyres
CR
Front ...................................................... PIRELLI SCORPION 60/100 12” 36M
Rear.................................................... PIRELLI SCORPION 2.75 -10 37J NHS
SM ..............................................SAVATECH 3.50-10 51P TL MC31 S-RACER
Cold tyre pressure
Front ................................................................................................. 1.2 Kg/cm2
Rear.................................................................................................. 1.5 Kg/cm2
Electrical components location
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic transducer under the fuel tank;
- Spark plug on cylinder head;

A.5Ed. 01-09-2010
GENERAL INFORMATION
Overall dimensions - Weight
Kerb weight, without fuel .......................................................... 43.4 kg (95.6 lb)
*: max. width
Capacities Type Quantity
Fuel tank 3% fuel-oil mixture during running-in, then 2% 2.7 litres
Oil inside crankcase SAE 20/30 150 cc
(oil change)
Front fork oil CASTROL SYNTHETIC FORK OIL - 5W
Coolant CASTROL MOTORCYCLE COOLANT 0.55 litres
Front brake uid CASTROL RESPONSE SUPER (DOT 4)
Rear brake uid CASTROL RESPONSE SUPER (DOT 4)
Drive chain lubrication CASTROL CHAIN LUBE RACING
Grease lubrication CASTROL LM GREASE 2
Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS LIQUID FILLER
Air lter oil AGIP FORMULA FILTER "Foam air lter protection oil"
Air lter detergent AGIP "Filter clean foam air detergent uid"
IMPORTANT - Do not add any additives to fuel or lubricants.

B.1
B
Ed. 01-09-2010
MAINTENANCE
Section

B.2 Ed. 01-09-2010
MAINTENANCE
ENGINE
After the first 5 hours Every 20 hours Every 40 hours Once a year Before the compe- tition
Transmission fluid level check ● ●
Transmission fluid change ● ●
Engagement speed check ● ● ●
Spark plug check and/or change, electrode gap adjustment ●
Check of carburettor fixing onto intake manifold ●
Check for the presence of cracks on intake manifold ●
Idle speed adjustment (hot engine) ●
Washers of washer valve check ●
Clutch shoes wear ●
Clutch drum wear check ●
Water pump shaft and relevant bearing wear check ●
Water pump impeller wear check ●
Cylinder and piston wear check ●
Axle shafts offset check ●
Connecting rod big end bearing radial clearance check ●
Connecting rod big end bearing radial clearance ●
Connecting rod small end bearing radial clearance ●
Main bearing check ●
Crankshaft bearings and connecting rod big end bearing replacement ●
Carburettor float chamber emptying and cleaning ● ●

B.3Ed. 01-09-2010
MAINTENANCE
CHASSIS
After the first 5 hours Every 20 hours Once a year Before the compe- tition
Fork complete maintenance ●
Swinging arm mount cleaning and greasing ●
Steering bearing and seal cleaning and greasing ●
Brake fluid change ●
Brake fluid level, pad thickness, brake disc check ● ●
Brake hose condition check ● ●
Front lever and brake pedal operation check and adjustment ● ● ●
Braking system screw tightening check ● ● ●
Exhaust system check ●
Control cable lubrication and smoothness check ● ● ●
Air filter and air box cleaning ● ● ●
Shock absorber and fork operation check ● ●
Swinging arm mount check ● ●
Steering bearing check and/or adjustment ● ●
Screw tightening check ● ●
Spoke tension and rim concentricity check ● ● ●
Tyre pressure and conditions check ● ●
Chain, master link, front and rear sprocket wear check ● ● ●
Lubricating the chain ● ● ●
Wheel bearing clearance check ● ● ●

B.4 Ed. 01-09-2010
MAINTENANCE
CHECKS
Before every use After every cleaning After offroad use
Transmission fluid level check ●
Coolant level check ●
Brake fluid level check ●
Brake seal wear check ●
Brake operation check ● ●
Control cable lubrication and adjustment ●
Fork dust seal removal and cleaning ●
Chain cleaning, tensioning check and lubrication ● ●
Air filter and air box cleaning ●
Tyre pressure and wear check ●
Fuel pipe condition check ●

C.1
C
Ed. 01-09-2010
TROUBLESHOOTING
Section

C.2 Ed. 0-09-2010
TROUBLESHOOTING
ENGINE
Trouble Cause Remedy
Engine does not start or Insufcient compression
has starting trouble 1. Piston seized Replace
2. Connecting rod small or big end seized Replace
3. Worn piston rings Replace
4. Worn cylinder Replace
5. Cylinder head loosely tightened Tighten
6. Head gasket leaking Replace
7. Spark plug loose Tighten
Weak or no spark
1. Spark plug faulty Replace
2. Fouled or wet spark plug Clean or dry
3. Spark plug electrode gap too wide Adjust
4. Ignition coil faulty Replace
5. High-tension cables open circuit or shorted Check
Fuel does not reach the carburettor
1. Tank cap breather clogged Clean
2. Fuel cock clogged Clean
3. Fuel feed pipe clogged Clean
 4. Filteroncarburettorttingdirty Clean
 5. Floatervalveoroatersfaulty Replace
 6. Linkageisblockingoatervalve Release
Carburettor ooding
1. High fuel level in bowl Adjust
 2. Floatervalveoroaterswornorstuckopen Replaceorrelease
Engine stalls 1. Fouled spark plug Clean
easily 2. Carburettor jets clogged Clean
3. Low idle Adjust
Engine is noisy Noise seems to come from piston
1. Too much piston-to-cylinder clearance Replace
2. Worn piston rings or piston grooves Replace
3. Too much carbon build-up in
combustion chamber or on piston crown Clean
Noise seems to come from crankshaft
1. Worn main bearings Replace
2. Connecting rod big end has too much side
  clearanceorendoat Replace
3. Crankshaft gear damaged Replace
4. Crankshaft locknut loose Tighten