Husqvarna WRE 125 2011 Instruction manual

Workshop Manual
WRE 125 2011
SMS 125 2011
Ed. 05-2011

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 (05-2011)

a.1
H02627
1
FOREWORD, TABLE OF CONTENTS
Ed. 05-2011
1st edition (05-2011)
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.
WRE 125 2011
SMS 125 2011
WRE 125: ZKHH200AABV000000
SMS 125: ZKHH200ABBV000000

a.2
FOREWORD, TABLE OF CONTENTS
Ed. 05-2011
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
FOREWORD, TABLE OF CONTENTS
Ed. 05-2011
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 Figures...................................................................................X
Chassis and Wheels............................................................................................Y
NOTES
Unless otherwise specied, data and specications apply to all models.

b.1
b
IMPORTANT NOTICES
Ed. 05-2011
Section

b.2
H02628
WRE 125
H02629
SMS 125
SMS 125
H02630
H02631
SMS 125
IMPORTANT NOTICES
Ed. 05-2011
WREand SMSmodelsare STREETLEGAL motorcycles;theyareguaranteed
exempt from functional defects and covered with legal guarantee, as far as the
STANDARD CONFIGURATION IS MAINTAINED and the suggested mainte-
nance table, shown in Section B, is observed.
* 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;
* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must
followthemaintenanceprogrammeindicatedinSectionBbyhavingtherequired
maintenance inspections carried outatauthorised HUSQVARNAdealers. 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
A
GENERAL INFORMATION
Ed. 05-2011
Section

A.2
GENERAL INFORMATION
Ed. 05-2011
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.3
SECONDARY DRIVE (WRE).......................................................................A.4
SECONDARY DRIVE (SMS)........................................................................A.4
FINAL RATIOS (WRE)..................................................................................A.4
FINAL RATIOS (SMS)..................................................................................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
GENERAL INFORMATION
Ed. 05-2011
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 ..................................................................................... by electric pump
Primary drive transmission/Gearbox ...... by the oil contained in the crankcase
IGNITION
Type .........................................................................................electronic C.D.I.
Spark plug type..............................................CHAMPION QN 84/NGK BR9EG
Spark plug gap ................................................................... 0,6 mm (0.0236 in.)
FUEL SYSTEM
Type............................................................Carburettor DELL’ORTO VHST 28
Venturi diameter...................................................................... mm 28 (1.10 in.)
High speed jet...............................................................................................142
Low speed jet ................................................................................................38
Starting jet .....................................................................................................60
Main nozzle ........................................................................................... HN 268
Floater ........................................................................................................g 6,5
Throttle valve..................................................................................................55
Metering pin................................................................................................D 48
Metering pin slot......................................................................................2nd (*)
Idle mixture adjusting screw.............................................................1+1/2 turns
PRIMARY DRIVE
Drive pinion gear ....................................................................................... Z 22
Clutch ring gear.......................................................................................... Z 72
Transmission ratio .....................................................................................3,272
CLUTCH
Type.........................................oil bath multiple disc clutch, mechanical control
TRANSMISSION
Type............................................................................constant mesh gear type
Transmission ratio
1st gear......................................................................................2,692 (Z 35/13)
2nd gear ....................................................................................1,800 (Z 27/15)
3rd gear ....................................................................................1,333 (Z 24/18)
4th gear......................................................................................1,100 (Z 22/20)
5 th gear.....................................................................................0,954 (Z 21/22)
6 th gear ....................................................................................0,869 (Z 20/23)
(*): with washer between retainer and throttle valve

A.4
GENERAL INFORMATION
Ed. 05-2011
SECONDARY DRIVE (WRE)
Transmission sprocket ............................................................................... Z 13
Rear wheel sprocket................................................................................... Z 49
Transmission ratio.....................................................................................3,769
SECONDARY DRIVE (SMS)
Transmission sprocket................................................................................ Z 14
Rear wheel sprocket................................................................................... Z 49
Transmission ratio.....................................................................................3,500
Transmission chain dimensions .......................................................... 5/8”x1/4”
FINAL RATIOS (WRE)
1st gear....................................................................................................33,211
2nd gear ..................................................................................................22,204
3rd gear...................................................................................................16,447
4th gear ...................................................................................................13,569
5th gear ...................................................................................................11,775
6th gear ...................................................................................................10,727
FINAL RATIOS (SMS)
1st gear....................................................................................................30,839
2nd gear ..................................................................................................20,618
3rd gear...................................................................................................15,273
4th gear ...................................................................................................12,600
5th gear ...................................................................................................10,934
6th gear .....................................................................................................9,960
FRAME
Type................................. single frame, in circular sectioned tubes, in steel; rear steel chassis.
FRONT SUSPENSION
Type................................................ ”Upside-down” telescopichydraulicfrontforkwith advanced
axle; ...............................................stanchions tubes Ø 1.57 in. / ø 40 mm
Legs axis stroke................................................................... 260 mm (10.24 in.)
REAR SUSPENSION
Type......................................progressive with hydraulic single shock absorber
(spring preload adjustment)
Wheel stroke ...................................................................... 272 mm (10.71 in.)
FRONT BRAKE
Type................................. fixed disc Ø 260 mm (10.24 in.) with hydraulic control and floating calliper
REAR BRAKE
Type................................. fixed disc Ø 220 mm (8.66 in.) with hydraulic control and floating calliper
RIMS
Front (WRE) ......................................................................in light alloy: 1,6x21”
Front (SMS)....................................................................in light alloy: 2,50X17”
Rear (WRE).....................................................................in light alloy: 2,15x18”
Rear (SMS)......................................................................in light alloy: 1,85x19”
TIRES
Front
(WRE)................................................................................................. 90/90-21”
(SMS) ................................................................................................110/70-17”
Rear
(WRE)............................................................................................... 120/90-18”
(SMS) ...............................................................................................140/60-17”

A.5
GENERAL INFORMATION
Ed. 05-2011
Cold tire pressure
Front
Rider only ....................................................................... 1,2 Kg/cm2 (17.07 Psi)
Rider and passenger......................................................1,5 Kg/cm2(21.33 Psi)
Rear
Rider only .......................................................................1,5 Kg/cm2(21.33 Psi)
Rider and passenger......................................................1,8 Kg/cm2 (25.60 Psi)
Electrical components location
The ignition system includes the following elements:
- Generator, on the inner side of L.H. crankcase cover;
- Electronic ignition coil under the fuel tank;
- Electronic control unit under the saddle;
- Voltage regulator on the left side of the chassis, near the steering tube.
- Spark plug on cylinder head;
The electrical system includes the following elements:
- 12V-4Ah Battery under the saddle;
- Turning indicator asher on left side of rear chassis;
- Fuses located on services bracket on left hand side of subframe;
- Oil pump located on right hand side of rear subframe;
- Air temperature sensor located inside lter box, near oil pump.
- Engine temperature sensor;
- Headlamp with twin halogen bulb of 12V-35/35W and parking light bulb of 12V-3W;
- LED taillight;
- Turning indicators 12V-10W bulb;
- Horn up front on right side, near the radiator.

A.6
H02633
WRE 125
GENERAL INFORMATION
Ed. 05-2011
Overall dimensions
Wheelbase A
(WRE)................................................................................ mm 1462 (57.56 in.)
(SMS) ................................................................................ mm 1462 (57.56 in.)
Overall length B
(WRE)................................................................................ mm 2208 (86.93 in.)
(SMS) ................................................................................ mm 2145 (84.49 in.)
Overall width C.................................................................... mm 825 (32.48 in.)
Overall height D
(WRE)................................................................................ mm 1245 (49.01 in.)
(SMS) .................................................................................mm 1175 (46.26 in.)
Saddle height E
(WRE).................................................................................. mm 944 (37.16 in.)
(SMS) .................................................................................. mm 929 (36.57 in.)
Minimum ground clearance F
(WRE).................................................................................. mm 330 (13.00 in.)
(SMS) .................................................................................. mm 265 (10.43 in.)
Weight
Kerb weight, without fuel (WRE):........................................ 108 Kg (238,01ß lb)
Kerb weight, without fuel (SMS):...........................................111 Kg (244,71 lb)

A.7
H02634
SMS 125
GENERAL INFORMATION
Ed. 05-2011
Capacities Type Quantity
Fuel tank capacity (reserve included) 98 octane unleaded fuel 9,5 l - 2.09 Imp. Gall
2.51 U.S. Gall
Fuel reserve 2 l - 0.44 Imp. Gall
0.53 U.S. Gall
Oil tank capacity 0.176 Imp. Gall
0.211 U.S. Gall
Coolant capacity 0.22 Imp. Gall
0.26 U.S. Gal
Transmission oil 0.143 Imp. Gall
0.172 U.S. Gall
Engine lubricating oil CASTROL POWER 1 RACING 2T
Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 5W-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 CASTROL SYNTHETIC FORK OIL 5W 520 cm3
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
B
MAINTENANCE
Ed. 05-2011
Section

B.2
MAINTENANCE
Ed. 05-2011
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
ENGINE
PART
EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE
500 km (310 mi) 1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi) 20000 Km (12427 mi) AS REQUIRED
TRANSMISSION OIL C S S S S
ENGINE OIL C
COOLANT C C S C S X
SPARK PLUG C S S S S
PISTON/CYLINDER C C C C X
EXHAUST VALVE DECARBONIZING P P P P X
CLUTCH DISC C C C C X
AIR FILTER P P S P S
CARBURETOR:IDLE/CO C C
CARBURETOR C/P C/P C/P C/P C/P
EXHAUST VALVE CLEANING / OIL DRAINAGE P
WRE - SMS 125
LEGENDA
C: CHECK
P: CLEAN
C/P: CHECK / CLEAN
S: CHANGE

B.3
MAINTENANCE
Ed. 05-2011
SCHEDULED MAINTENANCE CHART
(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
CHASSIS
PART
EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE
3 HOURS
1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi) 20000 Km (12427 mi) AS REQUIRED
BRAKE FLUID C C S C S
BRAKE HYDRAULIC CONTROLS C C C C C X
BRAKE PADS WEAR C C C X
BOWDEN CABLES C L L L L X
THROTTLE C C C C C X
TYRE PRESSURE AND WEAR C C C C C
OILAND FUEL TANKS P P
FUEL HOSES AND FILTERS P P S P S
HEADLAMP BEAM HEIGHT C C C C C
LIGHTS/INDICATIONS/HORN C C C C C
BATTERY C C C C C
WHEEL SPOKES TENSION C C C C C
STEERING BEARINGS PLAY C C C
SECOND.DRIVE CHAIN/CHAIN TENS.ROLLERS C C C C C C
GEARB.OUTPUT SPROCKET/REAR SPROCKET C S C S
SIDE STAND SCREWS C C C C C
WHEEL HUB BEARINGS C C X
FRONT FORK FLUID S S
OVERALL TIGHTENING OF NUTSAND BOLTS C C C C C
LUBRICATION/GREASING L L L L L
LEGEND
C: CHECK
L: LUBRICATE
P: CLEAN
S: CHANGE
NOTES:
- REPLACE GASKETS AND SEALSAFTER EACH REMOVAL;
- REPLACE SCREWS AND BOLTS IF DAMAGED;
- PERFORM AGENERAL INSPECTIONAFTER RIDING ON MUDDY OR SANDY TERRAIN.
WRE - SMS 125