Husqvarna SMS 125 2011 Instruction manual

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
1
Workshop Manual Ed. 06-2011
FOREWORD, TABLE OF CONTENTS
1st edition (06-2011)
Printed in Italy
MODELS COVERED (from serial number onwards)
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com
Workshop Manual
1. Chassis serial number
TE 250 - 310 2011 I.E.
CR 125 2011
WR 125 2011
CR 125: ZKH4H00AABV050001
WR 125: ZKH4H00AABV000001

a.2
simbolo
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.

a.3
simbolo
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
b
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
A
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

A.3
CR 125 2011 - WR 125 2011
Workshop Manual Ed. 06-2011
GENERAL INFORMATION
Engine
Type.............................................................................. single cylinder, 2 stroke
Cooling ...................................................................................................... liquid
Bore......................................................................................... mm 54 (2.12 in.)
Stroke ................................................................................... mm 54,5 (2.14 in.)
Displacement.............................................................. cm3124,82 (7.61 cu. in.)
Compression ratio (with closed ports) ........................................................8,8:1
Starting
Type..................................................................................................... kick start
Timing system
Type....................................... reed valve at intake in the crankcase and H.T.S.
valve with mechanical control at the exhaust
Lubrication
Motore ..................................... 4% (1:25) of oil-gasoline mix during running in;
NOT LESS than 3% (1:33) when running in is over
Primary drive transmission/Gearbox ...... by the oil contained in the crankcase
Ignition
Type ................. electronic digital capacitor-discharge type, with variable advance
Spark plug type..............................................CHAMPION QN 84/NGK BR9EG
Spark plug gap ................................................................... 0,6 mm (0.0236 in.)
Fuel system
Type..................................................................... Carburettor “Mikuni” TMX 38
Venturi diameter ...................................................................... mm 38 (1.50 in.)
High speed jet (CR)......................................................................................460
High speed jet (WR) .....................................................................................380
Low speed jet (CR).........................................................................................35
Low speed jet (WR)........................................................................................15
Starting jet (CR)..............................................................................................80
Starting jet (WR).............................................................................................50
Main nozzle ........................................................................................ R-8 (914)
Floater (n°2) ...............................................................................................g 6,1
Throttle valve (CR) ........................................................................................4,0
Throttle valve (WR)........................................................................................5,0
Metering pin...........................................................................................6BFY43
Metering pin slot (CR)................................................................................... 3rd
Metering pin slot (WR)..................................................................................2nd
Idle mixture adjusting screw (CR).....................................................1+1/4 turns
Idle mixture adjusting screw (WR)....................................................1+1/2 turns
Primary drive
Drive pinion gear ....................................................................................... Z 22
Clutch ring gear .......................................................................................... Z 71
Transmission ratio .....................................................................................3,227
Clutch
Type.........................................oil bath multiple disc clutch, mechanical control
Transmission
Type............................................................................ constant mesh gear type

A.4
CR 125 2011 - WR 125 2011
GENERAL INFORMATION
Workshop Manual Ed. 06-2011
Transmission ratio
1st gear...................................................................................... 2,357 (z 33/14)
2nd gear .................................................................................... 1,866 (z 28/15)
3rd gear .................................................................................... 1,579 (Z 30/19)
4th gear...................................................................................... 1,350 (Z 24/22)
5 th gear..................................................................................... 1,181 (Z 26/22)
6 th gear .................................................................................... 1,000 (Z 21/21)
SECONDARY DRIVE
Transmission sprocket ............................................................................... Z 13
Rear wheel sprocket................................................................................... Z 50
Transmission ratio .....................................................................................3,846
Transmission chain dimensions .......................................................... 5/8”x1/4”
FINAL RATIOS
1st gear....................................................................................................29,258
2nd gear ..................................................................................................23,170
3rd gear ...................................................................................................19,599
4th gear ...................................................................................................16,757
5th gear ...................................................................................................14,699
6th gear ...................................................................................................12,412
FRAME
Type..........................................................Steel single tube cradle (roud tubes);
light alloy rear frame.
FRONT SUSPENSION
Type............................................”Upside-down” telescopic hydraulic front fork
with advanced axle (adjustable in compression and rebound stroke);
stanchions tubes Ø 1.89 in.
Legs axis stroke....................................................................300 mm (11.80 in.)
REAR SUSPENSION
Type...................................... progressive with hydraulic single shock absorber
(spring preload adjustment)
Wheel stroke ....................................................................... 296 mm (11.65 in.)
FRONT BRAKE
Type.............................................................. xed disc Ø 10.24 in. “Wave” type
with hydraulic control and oating caliper
REAR BRAKE
Type........................................................... oating disc, Ø 9.45 in. “Wave” type
with hydraulic control and oating caliper
RIMS
Front ..................................................................................in light alloy: 1,6x21”
Rear (CR) ........................................................................in light alloy: 2,15x19”
Rear (WR) .......................................................................in light alloy: 2,15x18”
Tires
Front
(CR).................................................................................................. 80/100-21”
(WR) ................................................................................................... 90/90-21”
Rear
(CR).................................................................................................. 100/90-19”
(WR) ................................................................................................. 120/90-18”

A.5
CR 125 2011 - WR 125 2011
Workshop Manual Ed. 06-2011
GENERAL INFORMATION
Cold tire pressure
(front) (*) ....................................................................................... 12.8÷14.2 psi
( front) (%) ............................................................................................. 15.6 psi
(rear) (*)........................................................................................ 11.4÷12.8 psi
(rear) (%) ............................................................................................... 14.2 psi
(*) Racing use - (%) Road use
Electrical components location
The ignition system includes the following elements:
- Generator, on the inner side of L.H. crankcase cover;
- Spark plug on cylinder head;
(CR)
- Electronic ignition coil under the fuel tank;
- Electronic control unit positioned on left-hand side, under tank.
(WR)
- Transducer secured onto a bracket under fuel tank;
- Voltage regulator secured onto a bracket close to transducer.
(WR)
The electrical system includes the following elements:
- Flashing indicator device under the fuel tank
- Headlamp with twin halogen bulb of 12V-35/35W and parking light bulb of 12V-5W;
- LED taillight;
- Turning indicators 12V-10W bulb;
- Horn up front on right side, near the radiator.

A.6
CR 125 2011 - WR 125 2011
H06666
CR 125
GENERAL INFORMATION
Workshop Manual Ed. 06-2011
Overall dimensions
Wheelbase A
(CR)................................................................................... mm 1460 (57.48 in.)
(WR) .................................................................................. mm 1465 (57.68 in.)
Overall length B
(CR)..................................................................................... mm 2215 (87.2 in.)
(WR) .................................................................................. mm 2260 (88.98 in.)
Overall width C
(CR)..................................................................................... mm 820 (32.28 in.)
(WR) .................................................................................... mm 840 (33.07 in.)
Overall height D
(WRE)................................................................................ mm 1305 (51.38 in.)
(WR) .................................................................................. mm 1300 (51.18 in.)
Saddle height E
(CR)..................................................................................... mm 985 (38.78 in.)
(WR) .................................................................................... mm 975 (38.39 in.)
Minimum ground clearance F
(CR)..................................................................................... mm 325 (12.08 in.)
(WR) .................................................................................... mm 315 (12.04 in.)
Weight
Kerb weight, without fuel (CR):................................................92 Kg (202,83 lb)
Kerb weight, without fuel (WR):...............................................96 Kg (211,64 lb)

A.7
CR 125 2011 - WR 125 2011
H06667
WR 125
Workshop Manual Ed. 06-2011
GENERAL INFORMATION
Capacities Type Quantity
Fuel tank capacity (reserve included) 98 octane unleaded fuel 7 l -1.54 Imp. Gall
1.59 U.S. Gall
Fuel reserve 1,5 l - 0.33 Imp. Gall
0.34 U.S. Gall
Coolant capacity 0.24÷0.29 Imp. Gall
0.25÷0.3 U.S. Gal
Transmission oil 0.18 Imp. Gall
0.18 U.S. Gall
Engine lubricating oil CASTROL A747
Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 10W-40
Engine coolant CASTROL MOTORCYCLE COOLANT
Brake system uid CASTROL RESPONSE SUPER DOT 4
Grease lubrication CASTROL LM GREASE 2
Final drive chain lubrication CASTROL CHAIN LUBE RACING
Front fork oil KHL15-11 (CR) 352 cm3
(WR) 643 cm3
140 mm
Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS TURAFALLE LIQUIDO
IMPORTANT - Do not add any additives to fuel or lubricants.

B.1
CR 125 2011 - WR 125 2011
B
Workshop Manual Ed. 06-2011
MAINTENANCE
Section

B.2
CR 125 2011 - WR 125 2011
MAINTENANCE
Workshop Manual Ed. 06-2011
WR - CR 125
Competition motorcycle, racing use:
with full power engine
SCHEDULED MAINTENANCE CHART
ENGINE
ITEM
COUPON COUPON COUPON COUPON COUPON REPLACE IF NEC-
ESSARY
AFTER FIRST
4 hours
EVERY
4h CR/8h WR
EVERY
8h CR/16h WR
EVERY
16h CR/32h WR
EVERY
32h CR/64h WR
EVERY
40h CR/80h WR
CYLINDER ASSY . C X
REED VALVE C X
PISTON ASSY. S
CONNECTING ROD ASSY. S
EXHAUST VALVE DRIVE REGULATOR C
EXHAUST VALVE FORK S
EXHAUST VALVE COUNTERSHAFT S
EXHAUST VALVE CONTROL ROD S
EXHAUST VALVE P
TRANSMISSION OIL S S
SET OF MATCHED PRIMARY C X
CLUTCH DISCS HOUSING C X
CLUTCH DISCS C X
CLUTCH DISCS PRESSURE PLATE C X
CLUTCH SPRING C X
CLUTCH DISCS HOUSING C X
CLUTCH DISENGAGEMENT ROD C X
CLUTCH CONTROL SHAFT C X
CLUTCH SPRING PLATE C X
LEGEND
C: CHECK
L: LUBRICATE
P: CLEAN
S: CHANGE
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.

B.3
CR 125 2011 - WR 125 2011
Workshop Manual Ed. 06-2011
MAINTENANCE
WR - CR 125
Competition motorcycle, racing use:
with full power engine
SCHEDULED MAINTENANCE CHART
CHASSIS
ITEM
COUPON COUPON COUPON COUPON COUPON REPLACE IF
NECESSARY
AFTER FIRST
4 hours
EVERY
4h CR/8h WR
EVERY
8h CR/16h WR
EVERY
16h CR/32h WR
EVERY
32h CR/64h WR
EVERY
40h CR/80h WR
DRIVE SPROCKET C X
STARTING PEDAL L
GEAR CONTROL PEDAL C X
SPARK PLUG S
SPARK PLUG CAP C X
CARBURETOR ASSY. P R
AIR FILTER C / P X
AIR FILTER BOX/CARBURETOR MANIFOLD C X
RADIATORS C X
COOLANT HOSES AND CLAMPS C X
COOLANT C X
FOOTRESTS, FOOTREST PINS AND SPRINGS C X
SADDLE FRAME FASTENING BOLTS, ENGINE
FASTENING BOLTS C C
SIDE STAND C
CHAIN GUIDE ROLLER, BEARINGS C
STEERING HEAD, STEERING CROWN WITH PIN L
FRONT FORK R
HANDLEBAR HOLDERS AND FASTENING SET C C
REAR SWING ARM BUSHINGS C
REAR CHAIN SLIDER C X
REAR SUSPENSION LINKS BUSHINGS C
REAR CHAIN GUIDE/REAR CHAIN GUARD C X
REAR SWING ARM PIVOT NEEDLE BEARINGS L
REAR SHOCK ABSORBER R
REAR SUSPENSION LINKS NEEDLE BEARINGS
AND GUDGEON PIN L
THROOTLE CONTROL ASSY. C, L
CLUTCH CONTROL ASSY. C
THROOTLE AND CLUTCH CABLES C L X
FRONT BRAKE DISC C X
FRONT BRAKE SYSTEM FLUID C S
REAR BRAKE DISC C X
REAR BRAKE SYSTEM FLUID C S

B.4
CR 125 2011 - WR 125 2011
MAINTENANCE
Workshop Manual Ed. 06-2011
LEGEND
C: CHECK
L: LUBRICATE
P: CLEAN
S: CHANGE
NOTES:
- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.
WR - CR 125
Competition motorcycle, racing use:
with full power engine
SCHEDULED MAINTENANCE CHART
CHASSIS
ITEM
COUPON COUPON COUPON COUPON COUPON REPLACE IF
NECESSARY
AFTER FIRST
4 hours
EVERY
4h CR/8h WR
EVERY
8h CR/16h WR
EVERY
16h CR/32h WR
EVERY
32h CR/64h WR
EVERY
40h CR/80h WR
BRAKE PADS C X
BRAKE SYSTEM PUMP/CALIPER HOSES C
FUEL HOSES C S X
EXHAUST SILENCER PACK C X
EXHAUST PIPE AND SILENCER C X
WHEEL SPOKES TENSION C C
WHEEL HUB BEARINGS S
REAR DRIVEN SPROCKET S
REAR DRIVEN SPROCKET SCREWS
TIGHTENING C C
REAR TRASMISSION CHAIN C,L S X
BOLTS AND NUTS TIGHTNESS C C