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"

A.5Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Cold tyre pressure (TE)
Front
Rider only ............................................................................................ 17.07 Psi
Rider and passenger ............................................................................. 21.5 Psi
Rear
Rider only ............................................................................................ 21.33 Psi
Rider and passenger ............................................................................. 25.5 Psi
Cold tyre pressure (SMS)
Front
Rider only ............................................................................................ 21.33 Psi
Rider and passenger ............................................................................. 28.5 Psi
Rear
Rider only .............................................................................................. 28.5 Psi
Rider and passenger ............................................................................. 31.5 Psi
Electrical components location (TE)
The ignition system includes the following elements:
- Generator on the inner side of L.H. crankcase half cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the fuel tank;
- Voltage regulator under the fuel tank;
- Spark plug on cylinder head;
- 12V-450W starter motor behind the engine cylinder;
- Solenoid starter on the left of rear chassis;
The electrical system includes the following elements:
- 12V-6Ah battery under the saddle;
- Turning indicator asher on left side of rear chassis;
- Relay for electric fan, fuel injection system and lights on right side of chassis;
- Electric fan;
- Fuse located on the left side of the rear subframe;
- Air temperature sensor located on air box;
- Coolant temperature sensor;
- Headlamp with 12V-60-55/W twin halogen bulb and 12V-5W parking light bulb;
- Tail light with 12V-21/W stop lamp and 12V-5W parking light lamp;
- 12V-10W turning indicator bulbs;
- Odometer.

A.6
H02401
800 mm (31,50 inch) *
1230 mm (48,43 inch)
305 mm (12,01 inch)
2235 mm (87,99 inch)
930 mm (36,61 inch)
1450 mm (57,09 inch)
TE
Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
*: Max. Width
Overall dimensions - Weight
Kerb weight, without fuel (TE-SMS): .....................................117 Kg (257.94 lb)

A.7
H02402
800 mm (31,50 inch) *
1170 mm (46,06 inch)
255 mm (10,04 inch)
2200 mm (86,61 inch)
900 mm (35,43 inch)
1465 mm (57,68 inch)
SMS
Part. N. 8000 H4704 (07-2010)
GENERAL INFORMATION
Capacities Type Quantity
Fuel tank, reserve included 98 octane unleaded fuel 9,5 litres (2,09 gal.)
Reserve fuel 2 litres (0,44 gal.)
Gearbox/engine oil CASTROL POWER 1 RACING (SAE 10W50) 1,15 litres (0,3 gal.)
(oil change and oil lter
replacement)
0,95 litres (0,25 gal)
(oil change)
Front fork oil CASTROL SYNTHETIC FORK OIL (5W)
Coolant CASTROL MOTORCYCLE COOLANT 1,2 litres (0,32 gal.)
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
IMPORTANT - Do not add any additives to fuel or lubricants.
*: Max. Width

b.1Part. N. 8000 H4704 (07-2010)
b
IMPORTANT NOTICES
Section

b.2 Part. N. 8000 H4704 (07-2010)
TE
SMS4
IMPORTANT NOTICES
TE and SMS4 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.
IMPORTANT
VEHICLE CONFIGURATION as outlined below is a prerequisite for the warranty
to remain valid:
A) STANDARD MOTORCYCLE, FOR ROAD USE.
* 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.

F.1Part. N. 8000 H4704 (07-2010)
TECHNICAL DATA
F
Section

F.2 Part. N. 8000 H4707 (07-2010)
TECHNICAL DATA
Technical data: Engine ................................................................................. F.3
Technical data: Electrical system.................................................................. F.9
Technical data: Tightening torque gures .................................................. F.10
Technical data: Engine torque gures ........................................................F.11
Technical data: Lubrication points and types of Lubricant.......................... F.14
Technical data: Diagrams and Tables about the Lubrication System ......... F.16

F.3Part. N. 8000 H4704 (07-2010)
TECHNICAL DATA
ENGINE TECHNICAL DATA
Engine
Engine type• .................................................................................................................................4-stroke, liquid cooled, SOHC
Displacement• ............................................................................................................................................................ 124.7 cm3.
Cylinders layout• ............................................................................................................................. Single-cylinder tilted forward
Bore x stroke• ............................................................................................................................ 52.0 x 58.6 mm (2.05 x 2.31 in)
Compression ratio• ...........................................................................................................................................................11.20:1
Standard compression value (at sea level)• .......................................................................550 kPa/600 rpm (78.2 psi/600 rpm)
................................................................................................................................................................. (5.5 kgf/cm2/600 rpm)
Minimum-maximum• ........................................................................................... 480-620 kPa (68.3-88.2 psi) (4.8-6.2 kgf/cm2)
Starting system• ...................................................................................................................................... Electric starting device
Fuel
Recommended fuel• ...................................................................................................................................... Only unleaded fuel
Engine oil
Lubrication system• ..................................................................................................................................................... Wet sump
Type• ......................................................................... SAE 10W-30, SAE 10W-40, SAE 15W-40, SAE 20W-40 or SAE 20W-50
Recommended engine oil grade• ................................................................. API service type SG or higher, JASO standard MA
Engine oil capacity
Total quantity• .............................................................................................................................1.15 L (1.22 USqt) (1.01 Imp.qt)
Withoutreplacingtheoillter• ..................................................................................................0.95 L (1.00 US qt) (0.84 Imp.qt)
Whenreplacingtheoillter• .....................................................................................................1.00 L (1.06 US qt) (0.88 Imp.qt)
Oil lter
Typeofoillter• ..................................................................................................................................................................Paper
Oil pump
Type of oil pump• .........................................................................................................................................................Trochoidal
Internal rotor-external rotor end clearance• ....................................................................................... Below 0.15 mm (0.0059 in)
Limit• ........................................................................................................................................................... 0.23 mm (0.0091 in.)
External rotor-oil pump housing clearance• .............................................................................0.13-0.18 mm (0.0051-0.0071 in)
Limit• ............................................................................................................................................................ 0.25 mm (0.0098 in)
Oil pump housing-internal and external rotor clearance• .........................................................0.06-0.11 mm (0.0024-0.0043 in)
Limit• ............................................................................................................................................................ 0.18 mm (0.0071 in)
Safety valve operating pressure• ......................................................................39.2-78.4 kPa (5.7-11.4 psi) (0.39-0.78 kgf/cm2)
Pressure pick-up point• ........................................................................................................... Check bolt on cylinder head body
Thermostat
Model/manufacturer• ......................................................................................................................5YP/NIPPON THERMOSTAT
Valve opens at• .............................................................................................................................80.5-83.5 °C (176.9-182.3 °F)
Valve completely opens at• ............................................................................................................................. 95.0 °C (203.0°F)
Valve lift (fully open)• .......................................................................................................................................... 3.0 mm (0.12 in)
Radiator
Width• ............................................................................................................................................................ 198.0 mm (7.80 in)
Height• ........................................................................................................................................................... 128.0 mm (5.04 in)
Depth• .............................................................................................................................................................. 24.0 mm (0.94 in)
Water pump
Water pump type• ....................................................................................................................... Single suction centrifugal pump
Reduction Transmission ratio• ................................................................................................................................19/38 (0.500)
Spark plug(s)
Manufacturer/model• .................................................................................................................................................NGK/CR8E
Electrode gap• .................................................................................................................................0.7-0.8 mm (0.028-0.031 in)

F.4 Part. N. 8000 H4707 (07-2010)
1
2
3
4
TECHNICAL DATA
Cylinder head
Volume• ................................................................................................................................... 9.90-10.50 cm3 (0.60-0.64 cu.in)
Deformation limit• ........................................................................................................................................ 0.03 mm (0.0012 in)
Camshaft
Transmission system• .........................................................................................................................................Chain-drive (left)
Camshaft lobe dimensions
Intake A
• ...........................................................................................................................30.225-30.325 mm (1.1900-1.1939 in)
Limit• ........................................................................................................................................................ 30.125 mm (1.1860 in)
Intake B
• .............................................................................................................................................................. 25.114 - 25.214
Limit• .................................................................................................................................................................................. 25.014
Exhaust A• ........................................................................................................................................................... 30.261 - 30.361
Limit• .................................................................................................................................................................................. 30.161
Exhaust B• ........................................................................................................................................................... 25.172 - 25.272
Limit• .................................................................................................................................................................................. 25.072
Camshaft offset limit
• .................................................................................................................................. 0.030 mm (0.0012 in)
Timing chain
Model/number of links• ............................................................................................................................... DID SCR-0404SV/96
Tensioning system• ....................................................................................................................................................... Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter
• .............................................................................................9.985-10.000 mm (0.3931-0.3937 in)
Limit• ........................................................................................................................................................ 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter• ....................................................................................9.966-9.976 mm (0.3924-0.3928 in)
Limit• .......................................................................................................................................................... 9.941 mm (0.3914 in)
Rocker arm-rocker arm shaft clearance• .............................................................................0.009-0.034 mm (0.0004-0.0013 in)
Limit• .......................................................................................................................................................... 0.074 mm (0.0029 in)
Valve, valve seat, valve guide
Valve clearance (with cold engine)
Intake
• ......................................................................................................................................0.10-0.14 mm (0.0039-0.0055 in)
Exhaust• ...................................................................................................................................0.20-0.24 mm (0.0079-0.0094 in)
Valve dimensions
(Intake) valve head A diameter
• ...........................................................................................19.40-19.60 mm (0.7638-0.7717 in)
(Exhaust) valve head A diameter• .......................................................................................16.90-17.10 mm (0.6654-0.6732 in)