Husqvarna TE 125 Instruction manual

Workshop Manual
TE 125 2011
SMS4 2011
Part. N. 8000H4704 (07-2010)

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 (07-2010)

a.1
1
Part. N. 8000 H4704 (07-2010)
FOREWORD, TABLE OF CONTENTS
1st edition (07-2010)
Printed in Italy
Print no. 8000H4704
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 125 2011
SMS4 2011
TE 125: ZKHA500AABV000001
SMS 4: ZKHA500ABBV000001

a.2 Part. N. 8000 H4704 (07-2010)
FOREWORD, TABLE OF CONTENTS
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.3Part. N. 8000 H4704 (07-2010)
FOREWORD, TABLE OF CONTENTS
Table of Contents
Title Section
Foreword, table of contents................................................................................. a
Important notices ................................................................................................. b
General information.............................................................................................A
Engine Technical data .........................................................................................F
Engine overhaul.................................................................................................F1
Engine Maintenance..........................................................................................F2
Engine cooling ..................................................................................................F3
Carburettor ........................................................................................................F4
NOTES
Unless otherwise specied, data and specications apply to all models.

A.1
A
Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Section

A.2 Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Engine ..........................................................................................................A.3
Timing system ..............................................................................................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.4
Suspension...................................................................................................A.4
Brakes ..........................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres.............................................................................................................A.4
Electrical components location.....................................................................A.5
Overall dimensions - Weight.........................................................................A.6
Capacities.....................................................................................................A.7

A.3Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Engine
Single cylinder, 4 stroke
Bore........................................................................................................2.05 In.
Stroke .....................................................................................................2.05 In.
Displacement...................................................................................7,591 cu.In.
Compression ratio ....................................................................................11,2:1
Timing system
Type................................... single overhead camshaft; chain operated 4 valve
Valve clearance (with engine cold)
INTAKE..........................................................................0.0039 ÷ 0.0055 Inches
EXHAUST......................................................................0.0079 ÷ 0.0094 Inches
Fuel system
Type..................................................................................... "keihin" carburettor
Main jet.........................................................................................................122
Low speed jet .................................................................................................35
Air cleaning: dry air lter
Lubrication
Type......................................................................wet sump with cartridge lobes and filters
Cooling
Liquid with double radiator and heater fan
Ignition
Electronic, inductive with adjustable advance (digital control)
Spark plug type.............................................................................. "NGK" CR8E
Spark plug gap ........................................................................ 0.027 ÷ 0.031 In.
Starting ....................................................................................................electric
Transmission
Clutch: oil bath multiple disc clutch
Transmission: 6 gear ratios with constant-mesh gears
Motion is transmitted from engine to gearbox primary shaft through spur gears
Primary drive
Drive pinion gear ......................................................................................... z 24
Clutch ring gear ........................................................................................... z 73
Transmission ratio ..................................................................................... 3,042
Transmission ratio
1st gear....................................................................................... 2,833 (z 34/12)
2nd gear .....................................................................................1,875 (z 30/16)
3rd gear ......................................................................................1,364 (z 30/22)
4th gear ......................................................................................1,143 (z 24/21)
5th gear ......................................................................................0,957 (z 22/23)
6th gear ......................................................................................0,840 (z 21/25)
Secondary drive
Motion is transmitted from gearbox to rear wheel by 4/8" x 1/4"
Transmission sprocket ................................................................................ z 14
Rear wheel sprocket ( (TE).......................................................................... z 59
Rear wheel sprocket (SMS)......................................................................... z 54
Transmission ratio (TE) ............................................................................. 4,214
Transmission ratio (SMS).......................................................................... 3,857

A.4 Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Final ratios (TE)
1st gear...................................................................................................... 36,32
2nd gear .................................................................................................... 24,03
3rd gear ..................................................................................................... 17,48
4th gear ..................................................................................................... 14,65
5Th gear .................................................................................................... 12,26
6Th gear .................................................................................................... 10,77
Final ratios (SMS)
1st gear...................................................................................................... 33,24
2nd gear .................................................................................................... 22,00
3rd gear ..................................................................................................... 16,00
4th gear ..................................................................................................... 13,41
5Th gear .................................................................................................... 11,22
6Th gear ...................................................................................................... 9,86
Chassis
Single frame, in circular sectioned tubes, in steel; rear steel chassis.
Suspension
Front
”Upside-down” telescopic hydraulic front fork with advanced axle;tubes ø 40 mm;
Travel (mm) ................................................................................................. 260
Rear
Light alloy swingarm with progressive suspension and hydraulic monoshock.
Spring preload adjustment.
Wheel travel (TE) (in) .............................................................................. 11.42
Wheel travel (SMS) (in) ........................................................................... 11.10
Brakes
Front
Fixed disc ø 10.24 In. With floating calliper
Brake pad surface area ....................................................................... 16,2 cm2
Separate hydraulic circuit and master cylinder with control on right handlebar.
Rear
Brake pad surface area ....................................................................... 16,2 cm2
Separate hydraulic circuit, pedal and master cylinder on right side of vehicle.
Wheels
Rims
TE
Front ................................................................................. in light alloy: 1,6x21”
Rear................................................................................ in light alloy: 2,15x18”
SMS
Front ............................................................................... in light alloy: 2,50x17”
Rear................................................................................. in light alloy: 3,50x17”
Tyres
TE
Front ................................................................................................... 90/90x21"
Rear.................................................................................................. 120/90x18"
SMS
Front ................................................................................................. 110/70x17"
Rear.................................................................................................. 140/70x17"