CR 125
Contents
1. Husqvarna CR 125 CR 125 USA 2013 WR 125 WR 125 USA 2013 Plt Il x 11 PETE PPP EEE EE 5 OPERATION MAINTENANCE EN HEEE Ed 05 2012 Rev Unless specified data and prescription are referred to all the models TABLE OF CONTENTS Page Note e References to the left or right of the motorcycle are in 3 the sense of a person facing forwards IMPORTANT NOTICES 3 IDENTIFICATION DATA 5 MEE CR WR USA control location 6 in WR control EO Bel i 8 E PL LUBRICATION TABLE SUPPLIES 9 NE Gaal eee en 10 Switzerland RIDING 17 IGNITION SYSTEM ELETTRICAL 5 4 N U 44 EE od PRE DELIVERY 1 47 FIN Finland ALPHABETICAL INDEX 48 GB Great Britain PERIODIC MAINTENANCE ADJUSTMENT Appendix A E 1 J Japan USA United States of America e Where not specified all the data and the instructions are referred to any and all Countries SPECIFICATIONS OPERATION MAINTENANCE PRESENTATION Welcome to the Husqvarna motorcycling Family Your new2. 122 17 Transmission ratio 3 227 CLUTCH Type oil bath multiple disc clutch mechanical control TRANSMISSION constant mesh gear type Transmission ratio VS GOOF 2 357 2 33 14 2nd gear 1 866 z 28 15 SIO MOOD NETTE ET TEE TTC ET TT TIE 1 579 7 30 19 Ath gear 2 eee cee cece eee 1 350 Z 24 22 Sth gear 1 181 Z 26 22 1 000 21 21 SECONDARY DRIVE Transmission sprocket Rear wheel sprocket 113 150 Transmission 0 3 046 FINAL RATIOS OL 29 258 2 a 23 170 19 599 16 757 14 669 RR REED 12412 FRAME Steel single tube cradle roud tubes light alloy rear frame FRONT SUSPENSION Upside down telescopic hydraulic front fork with advanced PPP in compression and rebound stroke stanchions tubes 0 1 89 0 48 mm Legs axis 11 8 in 300 mm REAR SUSPENSION Type progressive with hydraulic single shock absorber Whee 11 6 in 296 mm FRONT BRAKE Typefixed disc 10 24 in 260 Wave type with hydraulic control and floating caliper REAR BRAKE Type floating disc
3. ODO 1 SPEED Km h or mph 0DO SPEED motorcycle speed maximum value 299 Km h or 299 mph ODO odometer maximum value 99999 km To replace kilometers with miles or miles with kilometers pro ceed as follows 1 set to figure 1 stop the engine and push the knob SCROLL A I 2 Start the engine holding pushed the button SCROLL A until the symbol Km h will be displayed 3 then the symbols Km h and Mph Miles will be displayed alternatively Push again the SCROLL A button when the unit you wish to use is displayed 30 34508 SPEED Kmh EN 12 SPECIFICATIONS OPERATION MAINTENANCE 11 ede 2 SPEED CLOCK SPEED motorcycle speedmaximum value 299 Km h o 299 mph CLOCK clock Reading from 0 00 to 23 59 59 To reset the clock push the knob SCROLL A for more than 3 seconds in order to increase the hours release the knob and then after 3 seconds it is possible to increase the minutes 850 SPEED Km h 3 SPEED TRIP 1 SPEED motorcycle speedmaximum value 299 Km h o 299 mph TRIP 1 distance maximum value 999 9 km the data will be lost with voltage lower than 6V To setup the TRIP push the SCROLL A button holding down more than 3 seconds 8 SPEED Km h 4 SPEED CHRONO STP uin motorcyde speedmaximum value 299 Km h o 299 STP 1 miles kilometers covered time Reading
4. The rear brake 3 foot pedal should have a B 5 mm 0 2 in idle stroke before starting the true braking action Should this not happen operate as follows loosen nut 4 operate the pump rod 5 to increase or decrease the idle stroke tighten nut 4 at the end of the operation WARNING When the idle stroke figures are not met the brake pads will be subjected to a fast wear that may bring to the TOTAL BRAKE INEFFEC TIVENESS CHECKING THE FLUID LEVEL The level A must be set between the pump tank notches Me SPECIFICATIONS OPERATION MAINTENANCE 27 BEBE m E ADJUSTING THE SUSPENSIONS ACCORDING TO PARTICULAR TRACK CONDITIONS The following information is a useful guide for setting up the suspensions according to the road conditions Always start from the standard calibration before making any change on the suspensions Afterwards increase or decrease the adjusting clicks one at a time HARD GROUND Fork softer compression adjustment Shock absorber softer compression adjustment The softer adjustment for the two suspensions is also used both in compression and in extension when driving at top speed in order to have better grip of the tires SANDY GROUND Fork have a harder compression adjustment or replace the standard spring with a harder one and make a softer compres sion adjustment and a harder extension adjustment at the same time Shock absorber
5. 2 set on left side of tank has three positions OFF closed no fuel outlet ON open fuel outflows from the main flow RES reserve fuel outflows from the reserve flow When running should feed problem ensue set cock lever on RES position After filling up take the cock in ON position again SIDESTAND A sidestand 1 is supplied with every motorcycle WARNING The stand is designed to sup port the weight of the MOTORCYCLE ONLY Do not sit on the motorcycle using the stand for support as this could cause structural failure to the stand and could cause serious bodily injury WR Periodically check the side stand see Periodical mainte nance card check that the springs are not damaged and that the side stand freely moves If the side stand is noisy lubricate the fastening pivot A EN 10 SPECIFICATIONS OPERATION MAINTENANCE FUEL The motorcycle is equipped with 2 stroke engine that requires gasoline oil mixture Recommended fuel premium grade un leaded fuel R O N 98 Note Do not continue operation if the en gine pings or knocks The engine will be damaged and could seize WARNING If knocking or pinging occurs try a different brand of gasoline or higher octane grade WARNING Gasoline is extremely flamma ble and can be explosive under certain con ditions Always stop the engine and do not smoke or allow flames or sparks in the area where
6. 000001 dA DLL e 9 1 Frame serial number 2 Engine serial number 5 OPERATION MAINTENANCE EN 5 BERE CR WR USA CONTROL LOCATION 1 Front brake lever 2 Throttle grip 3 Engine stop button 4 Rear brake control pedal 5 Starting pedal 6 Clutch control lever 7 Fuel tank filler cap 8 Gearbox control pedal 9 Choke L H side 10 Fuel cock WR CONTROL LOCATION 1 Front brake lever 2 Throttle grip 3 L H commutator 4 Rear brake control pedal 5 Starting pedal 6 Clutch control lever 7 Fuel tank filler cap 8 Gearbox control pedal 9 Choke L H side 10 Fuel cock ELELEEEEELELLELEELELL TELLE EE EE E EE EE ORE HEURE SPECIFICATIONS OPERATION MAINTENANCE EN 7 BENE TECHNICAL DATA ENGINE single cylinder 2 stroke liquid MIC RR RR 2 13 in 54 mm 2 15 in 54 5 mm 7 62 in 124 82 cm Compression ratio with closed ports 8 8 1 Starting kick start TIMING SYSTEM M lamellar valve on suction in the crankcase and S valve with mechanical control on the exhaust 4 5 of oil gasoline mix ini runni
7. 17 BEBE ENGINE START For the correct start of a cold engine proceed as follows shift the transmission into neutral CR WR USA open cock 1 by loosening ring nut 2 WR set fuel valve 3 in ON position lift the knob lever 4 on the carburetor Leaving the throttle in closed position operate kick start 5 s the knoh lever in its initial position as soon as the engine is idling When caving with an already warmed up engine DO NOT USE the starter You can start the engine with the gear inserted after disconnecting of the clutch IF the carburetor is flooded shut off the fuel supply and the starter and operate the crank lever or the kick start until the engine starts If necessary remove the spark plug and dry it IMPORTANT NOTE IN CASE OF COLD STARTS AT LOW TEMPERATURES It is recommended to briefly warm up the en gine at idle until after having disengaged the starter there is a normal response from the engine when opening the throttle This will enable the lubricant to reach the cor red working temperature thereby guarantee ing a correct functioning of all engine parts Avoid overheating the engine IMPORTANT Never accelerate the engine after a cold start WARNING Exhaust contains poisonous car bon monoxide gas Never run the engine in a closed garage or in a confined area WARNING This high performance motor cycle can some times kick back strongly when you are starting it Do n
8. A ADJUSTING THE COMPRESSION 29 ADJUSTING THE SHOCK 30 ADJUSTING THE SUSPENSIONS ACCORDING TO PARTICULAR TRACK _ 28 ADJUSTMENT OF HEADLIGHT 43 ADJUSTMENT OF THE CLUTCH CONTROL LEVER 23 ADJUSTMENT OF THE CONTROL LEVER AND CHECK OF THE FRONT BRAKE FLUID LEVEL 26 AFTER RACE CHECK 44 AIR FILTER AND CLEANING 24 AIR FILTER 24 E 44 pa m 24 B BRAKE DISC 40 BRAKE PADS 39 DRARES eee 38 C CARBURETOR 1 CHAIN 5 32 CHANGING TRANSMISSION GEARBOX 0 20 CHECKING THE FLUID LEVEL ne 2 CHECKING THE WEAR OF CHAIN PINION AND SPROC
9. Husqvarna motorcycle is designed and manufac tured to be the finest in its field The instructions in this book have been prepared to provide a simple and understandable guide for your motorcycle s operation and care Follow the instructions carefully to obtain maximum per formance and your personal motorcycling pleasure Your owner s manual contains instructions for owner care and maintenance The main work of repair or maintenance requires the at tention of a skilled mechanic and the use of special tools and equipment Your Husqvarna dealer has the facilities experience and origi nal parts necessary to properly render this valuable service This Owner s Manual is part and par cel of the motorcycle hence this had to remain with the motorcycle even when sold to another user This motorcycle uses components designed thanks to sys tems and state of the art technologies which are thereafter tested in competition In competition motorcycles every detail is verified after each race in order to always guarantee better performance For correct functioning of the vehicle it is necessary to follow the maintenance and control table found on Appendix A IMPORTANT NOTICES 1 The CR models are guaran teed COMPETITION motorcycles exempt from functional detects the suggested maintenance ta ble for competition use is shown on Appendix A 2 WR vehicles are STREET LEGAL motorcycles with LIMITED POWER ENGINE they are gua
10. oil drain completely then screw the cap back on with its seal and pour fresh oil through the filler hole Use only the prescribed quantity and type of oil EN 20 SPECIFICATIONS OPERATION MAINTENANCE PEP b iii bib bbb bib ib ib rb bib rrr ribs COOLANT LEVEL CHECK Check level 1 in right hand radiator when engine is cold place the motorcycle so that it is perpendicular to the ground The coolant should be approximately 0 39 in above the cells The radiator cap features two locking positions the first one is for prior discharge of pressure from the cooling system WARNING Avoid removing radiator cap when engine is hot as coolant may spout out and cause scalding NOTE Difficulties may arise in eliminating coolant from varnished surfaces If this occurs wash off with water COOLANT REPLACEMENT Place the vehicle on a flat ground and in horizontal position Place a vessel of adequate capacity on the right side of the vehicle under the water pump 1 Loosen the exhaust screw 2 using an 8 mm wrench Slowly open the RH radiator cap 3 and let the liquid drain After drain tighten the screw 2 replacing the aluminium sealing washer WARNING Avoid removing radiator cap when engine is hot as coolant may spout out and cause scalding WARNING Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water pour the necessary quantity
11. taught it could escape from sprock et or break To adjust the rear chain it is necessary to lower the rear part of motorcycle so to line up the drive sprocket axle the rear swing arm axle and the rear wheel axle as shown on drawing Than let turn three times the rear wheel Now the chain should not be tight i E Drive sprocket axle E _ I I TN ee Rear swing arm axle Quick adjustment Insert a 35 mm socket a or a shim of the same size at the position shown in the figure and check that the lower section C of the chain is slightly taut If it is not proceed as follows Loosen the wheel axle nut 1 on the right hand side using a 27 mm socket wrench Loosen the check nuts 2 on both chain tensioners with a 12 mm wrench and work the screws 3 until achieving the correct tension When the adjustment is completed tighten the check nuts 2 and the wheel axle nut 1 After any adjustment always check wheel alignment and tight en wheel axle securely Rear wheel axle EN 32 SPECIFICATIONS OPERATION MAINTENANCE CHECKING THE WEAR OF CHAIN PINION AND SPROCKET Check the pinion damages or wear and replace it should the wear degree be as the one shown in figure Remove the wheel and check the wear of the rear sproket teeth The below figure shows the outline of teeth in normal and exces sive wear Should the sprocket be badly worn out replace
12. the motorcycle is refueled or gasoline is stored WARNING Do not overfill the tank After re fueling make sure the tank cap 2 is closed securely CARBURETOR CHOKE The starter knob 1 located on the left side of the carburetor is used to enrich the mixture during the engine start Pull out the knob fo open the starter and pull the lever upwards to close it 1 5 OPERATION MAINTENANCE EN 1 BEBE DIGITAL INSTRUMENT WARNING LIGHTS WR The motorcycle is equipped with a digital instrument on the instrument are located 2 warning lights too high beam and blinkers 1 BLUE warning light HIGH BEAM 2 GREEN warning light BLINKERS The instrument display illuminates amber colour when the engine started NOTES Every time the engine starts for the first 2 seconds the instrument shows the version of the checking SW after the check the instrument shows the last planned function When the motorcycle engine is OFF the instrument doesn t also show its functions To select the instrument functions and to set to zero the functions use the SCROLL knob A A985 SPEED Kmh Mph Mies ODO LPT CLK The instrument functions are the following as shown below 1 SPEED 000 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED CHRONO 1 SPEED 000 me m 988888 SPEED Kmh Mph Miles
13. 06 in Disc Thi Replace the disc if warpage is more than service limit isc Thickness SERVICE DISC LIMIT Front 3mm 2 5 mm 0 12 in 0 1 in Poor braking can also be caused by oil on the disc Oil or grease on the disc must be cleaned off with a high flash point oil free solvent such as acetone or lacquer thinner 3 4 mm 0 134 in EN 40 SPECIFICATIONS OPERATION MAINTENANCE ELECTRICAL COMPONENTS LOCATION Voltage regulator 5 secured onto a bracket close to trans The ignition system includes the following elements ducer The electric system includes the following elements m iE Flashing indicator device 7 under the fuel tank EAE 1 in oil bath on the inner side L H crankcase Headlamp 8 with two filaments bulb of 12V 35 35W and a parking light bulb of 12V 5W plug 5 on the cylinder head Back light 9 LED type Turn signals bulb 10 of 12V 10W Electronic ignition coil 2 under the fuel tank Electronic control unit 3 positioned on left hand side under tank WR Transducer 4 secured onto a bracket under fuel tank ZB 1 cz w lt gt E 24 u HFH 1 rz A HEADLAMP BULBS REPLACEMENT WR gain access to the healamp bulbs proceede as follows remove the upper fastening screw of the the headlamp carrier to the instrument panuel support 1 push
14. 3 18 8 ft lb Spark plugs which have cracked insulators or corroded electrodes should be replaced 008 SPECIFICATIONS OPERATION MAINTENANCE 23 EEEE AIR FILTER CHECK Turn rear pin 1 counterclockwise remove the saddle from the front afstening screw Remove screw 3 and the filter 4 Separate filter 5 from frame 6 AIR FILTER AND CLEANING Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEANER or similar then dry it fully wash filter with gasoline only in case of necessity Plunge the filter in special oil for filters CASTROL FOAM AIR FILTER OIL or similar then wring it to drain superfluous oil CAUTION Do not use gasoline or a low flash point solvent to clean the element A fire or explosion could result CAUTION Clean the element in a well ven tilated area and do not allow sparks or flames anywhere near the working area ASSEMBLY To ensure tight fit slightly C grease filter edge on side facing filter housing While re inserting the filter into its housing make surs that piece A is turned upwards and edge B is on the left lower side of the filter case Reassemble the parts previously removed bat tery connect the positive cable first CAUTION If the element assembly is not installed correctly dirt and dust may enter and the engine resulting in rapid wear of the piston rings and cylinder EN 24 SPECIFICATIONS OPERATION MAINTENANC
15. 9 45 in 0240 Wave type with hydraulic control and floating caliper RIMS MULT ERR in light alloy 1 6x21 Rear in ight lloy 15 19 Rear in light alloy 2 15x18 TYRES Front We 80 100x21 A 90 90x21 Rear M 100 90x19 Rear 120 90x18 Cold tire pressure TG 12 8 14 2 psi 0 9 1 0 Kg cm ee ee 15 6 psi 1 1 Kg cm ar 11 4 128 psi 03 0 9 Kg cm 14 2 psi 1 0 Kg cm Racing use Road use DIMENSION WEIGHT CAPACITY Wheelbase 57 48 1460 Wheelbase WR 57 68 in 1465 mm Overall length CR 87 2 in 2215 mm Overall length WR 88 98 in 2260 mm Overall width 32 28 in 820 mm Overall width WR 33 07 in 840 mm Overall height CR 51 38 in 1305 mm Overall height WR 51 18 in 1300 mm Saddle height 38 78 in 985 mm Saddle height WR 38 38 in 975 mm Minimum ground cleara
16. E STEERING WHEEL BALL PLAY ADJUSTMENT To ensure maximum safety the steering wheel should always be regulated so that the handlebars steering the motorcycle rotate freely without play To check steering wheel adjustment place kick stand or other support under the engine so that the front wheel is raised from ground Place slight pressure on the tips of the handlebars to rotate steer ing wheel the handlebars should also rotate without effort Stand in front of the motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis Se si avverte gioco occorrer eseguire la regolazione operando come segue loosen steering sleeve nut 1 Loosen screws that fix steering head to fork rods 3 Turn the steering ring nut 2 clockwise of the steering sleeve proper tool to adjust play properly Tighten steering sleeve nut 1 to a torque setting of 57 9 65 Lb ft 78 4 88 3 Nm Tighten screws on the steering head 3 to a torque of 27 526 5 Nm 16 619 5 Lb ft CAUTION Do not ride a motorcde with damaged steering stem bearings An unsafe handling condition can result SPECIFICATIONS OPERATION MAINTENANCE EN 25 BERE ADJUSTMENT OF THE CONTROL LEVER AND CHECK OF THE FRONT BRAKE FLUID LEVEL The adjuster 2 located on the control lever allows adjusting of the free play a Free play a must be at least 0 39 in 10 mm The level of the fluid i
17. E UR EHE EE SPECIFICATIONS OPERATION MAINTENANCE 29 BEBE ADJUSTING THE SHOCK ABSORBER The rear shock absorber must be adjusted according to the rider weight and track conditions Proceed as follows 1 With motorcycle on the stand measure distance A 2 Take the normal riding position on the motorcycle with all your riding apparel 3 With somebody s help take the new distance A B axis of the panel screw C axis of rear wheel pin 4 The difference between these two measurements constitutes the SAG of the motorcycle s rear end The shock absorber lowering should be of about 100 mm 3 94 in 5 To get the right SAG according to your weight adjust the shock absorber spring preload as described at side WARNING Never disassemble shock ab sorber which contains highly compressed nitrogen Contact your Dealer for such major service Do not incinerate EN 30 SPECIFICATIONS OPERATION MAINTENANCE SHOCK ABSORBER SPRING PRELOAD ADJUST MENT Proceed as follows Place yourself on the right hand side of the motorcycle Clean ringnut 1 and adjusting nut 2 of the spring 3 Either with a hook wrench or an aluminium punch loosen the ringnut Turn the adjusting nut as required When the adjusting operation is over according to your weight and riding style tighten the ringnut Torque for both ringnuts 40 Nm 4 29 50 ft lb Rea
18. KET 33 CHECKS WHILE RUNNING 17 dir e 45 15 10 COOLANT LEVEL 2 COOLANT 2 CR WR USA CONTROL 10 0 6 CR FUEL 0 10 0 10 D DIGITAL INSTRUMENT WARNING LIGHTS WR 12 DISC 40 DISC WAR PAGE 40 E ELECTRICAL COMPONENTS LOCATION ENGINE STOP BUTTON CR WR USA G GEAR SHIFT CONTROL HANDLEBAR COMMUTATOR WR HANDLEBAR POSITION AND HEIGHT CHANGE HEADLAMP BULBS REPLACEMENT WR IDENTIFICATION DATA LUBRICATING THE CHAIN PRE DELIVERY INSPECTION R REAR BRAKE 16 REAR BRAKE IDLE STROKE 2 REAR BRAKE PEDAL POSITION ADJUSTMENT 7 REASSEMBLING THE FRONT 36 REMOVI
19. L Use NGK BR9EG or CHAMPION QN84 spark plug 2 the gap is 0 6 in A wider gap may cause difficulties in starting engine and in overloading coil A gap that is too narrow may cause difficulties when accelerat ing when idling the engine or when performing at low speeds Clean the dirt away from the base of the spark plug before re moving it from the cylinder after removing the cap 1 It is very useful to examine the state of the spark plug just after it has been removed from the engine since the deposits on the plug and the colour of the insulator provide useful indications Correct heat rating The tip of the insulator should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the spark plug is overheated and insulator tip is vitre ous white or grey in colour CAUTION Select a spark plug with a colder or hotter heat range carefully and cautiously A spark plug with too hot a heat range may lead to preignition and possible engine damage A spark plug with too cold a heat range may foul as the result of too much carbon buildup Before refitting the plug thoroughly clean the electrodes and the insulator using a brass met Apply a little graph he spark pl Apply a little graphite grease to the spark plu thread fit and screw the spark plug by han a then tighten to the torque of 23 5 25 5 Nm 17
20. NG THE FRONT WHEEL 35 REMOVING THE REAR 37 REPLACING THE NUMBER PLATE LAMP WR 43 z2 17 RUNNING IN 17 SHOCK ABSORBER DAMPING 5 31 SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 31 SIDESTAND c 10 SPARK 0 23 STEERING LOCK WR 14 STEERING WHEEL BALL PLAY ADJUSTMENT 25 STOPPING THE MOTORCYCLE AND THE ENGINE 19 STORAGE 44 T TABLE FOR LUBRICATION SUPPLIES 9 TAIL LIGHT WR 42 TECHNICAL DATA 8 THROTTLE CABLE 5 22 THROTTLE 14 TIRES 38 TRANSMISSION OIL LEVEL 20 Ww WR CONTROL LOCATION 7 WR FUEL COCK 10 EEEE EN 48 SPECIFICATIONS OPERATION MAINTENANCE
21. OR CR Wash using either oil or diesel oil When using gasoline or tri cloroetilene clean and lubricate the chain to prevent oxidation Washing the chain with OR WR Wash using oil diesel oil or paraffin oil Never use gasoline tricloroetilene or solvents as the OR may suffer damages Use instead special sprays for chains with OR Lubricating the chain without OR CR First dry then plunge the chain in a bisulphide molybdenum lubricant or in high viscosity engine oil Warm up the oil before use Note As an alternative you can use suitable spray lubri cants Lubricating the chain with OR WR Lubricate all metallic and rubber OR elements using a brush and use engine oil with SAE 80 90 viscosity for the internal and external parts Note As an alternative you can use suitable spray lu bricants 5 Assemble the joint spring a by turning the closed side to the chain direction of rotation as shown in figure below NOTE Even if all the joints are reusable when in good con ditions for safety purposes we advise using new joints when reassembling the chain 6 Correctly adjust chain as described in the relevant para graph 1 Chain tension roller 2 Chain guide 3 Chain slider a Joint spring WARNING The chain oil has NEVER to get in contact with the tires or the rear brake disk Chain tension rollers chain driving roller chain guide chain runner Check the wear of the above mentioned elements an
22. OR WR The left commutator has the following controls 1 Engine stop button 5 2 HI Selection control High beam LO 20 Selection control of Low beam 3 TURN Activation of left turn indicators self cancelling gt Activation of right turn indicators self cancelling To deactivate the indicator press the control lever after its re turning to center 4 HORN pon Warning horn 5 LIGHTS rr Lighting control of lowbeams and high beam 2005 Lighting control of position lights off ENGINE STOP BUTTON CR WR USA On the left side of the handlebar near the clutch control is lo cated the engine stop button 1 fe CLUTCH CONTROL The clutch lever 2 is located on the left hand side of the han dlebar and is protected against dirt filtering in The position of the clutch control on handlebar can be adjusted by loosening the retaining screws C CAUTION Do not forget to tighten the screws C after the adjustment ELELEEEEELELLLEELLTL TELLE EE EE E EE EE UE E HERE SPECIFICATIONS OPERATION MAINTENANCE 15 BENE REAR BRAKE CONTROL The rear brake control 1 is placed on the right hand side of the motorcycle On models WR a stop switch during the braking action causes the rear light to come on GEAR SHIFT CONTROL The lever 1 is placed on the left hand side of the engine The operator must release the lever after each gear change to allow it to r
23. PPENDIX AFTER RACE CHECK POINTS After racing first clean the motorcycle and then inspect the entire motorcycle with special attention to the items listed in MAINTENANCE table Appendix A such as the air cleaner carburetor brakes etc Carry out general lubrication and make adjustment as neces sary After every race always check the correct tightening of all screws and bolts STORAGE When the motorcycle is to be stored for any length of time is should be prepared for storage as follows Clean the entire motorcycle thoroughly Empty the fuel from the fuel tank and empty the carburetor float bowl If left in for a long time the fuel will deteriorate WARNING Never litter the environment with fuel and let the engine running in open air never in dosed rooms Lubricate the drive chain and all the cables Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards un der the front and rear wheels to keep dampness away from the tire rubber Tie a plastic bag over the exhaust pipe to prevent moisture from entering Put a cover over the motorcycle to keep dust and dirt from collecting on it To put the motorcycle back into the use after storage Make sure the spark plug is tight Fill the fuel tank Run the engin
24. ad In order to maintain the vehide s Guaran tee of Functionality the client must follow the maintenance program indicated in the user s manual by carrying out maintenance checks at authorized HUSQVARNA dealers The cost for substituting parts and for the la bour necessary in order to respec the main tenance plan is charged to the client NOTE the guarantee is EXTINGUISHED in the case where the motorcycle is rented Important Notice Read this manual carefully and pay special attention to state ments preceeded by the following words Warning Indicates a possibility of severe personal injury or loss of life if instructions are not followed Caution Indicates a possibility of personal injury or equipment damage if instructions are not followed Note Gives helpful information Parts Replacement When parts replacement is required use only Husqvarna ORIGI NAL parts Warning After an upset inspect the motor cycle carefully Make sure that the throttle brake dutch and all other systems are un damaged Riding with a damaged motorcycle can lead to a serious crash Warning Never attempt to start or operate your motorcycle unless you are wearing ap propriate protective clothing Always wear a motorcycle helmet motorcycle boots gloves goggles and other appropriate protective clothing Warning This motorcycle is a state of the art competition bike Do not attempt to start or ride this motorcyde unt
25. and disc a nk rect tyre inflation pressure 8 Rear brake caliper LEGEND i 9 Rear brake disc 1 Front brake control lever 10 Rear brake pump 2 Front brake pump with oil reservoir 3 Front brake hose 11 Rear brake control pedal EN 38 SPECIFICATIONS OPERATION MAINTENANCE BRAKE PADS REMOVAL PADS WEAR PADS CLEANING Inspect pads for wear Be careful that no disc brake fluid or any oil gets on brake pads Remove springs 1 Service limit A is 3 8 mm 0 15 or discs Clean off any fluid or oil that inadverently gets on the Remove pins 2 If service limit is exceeded always replace the pads in pairs pads or disc with alcohol a Remove pads Replace the pads with new ones if they cannot be cleaned sat istactorily CAUTION Don t operate the brake lever or pedal while PADS INSTALLATION removing the pads Install new brake pads Reassemble the two pins 2 and the springs 1 WARNING Do not attempt to ride the motorcyde until the brake lever or pedal are fully effective Pump the brake lever or pedal until the pads are against the discs The brake will not fundion on the first ap plication of the lever or pedal BRAKE DISC WEAR DISC WARPAGE DISC CLEANING Measure the thickness of each disc at the point where it has worn Measure disc warpage Service limit for both discs is 0 15 mm the most Replace the disc if it has worn past the service limit 0 0
26. d replace them when necessary WARNING Check the chain guide aligne ment and remember that a bent element can cause a rapid wear of the chain In this case a chain fleeting from the sprocket may ensue EEEE EN 34 SPECIFICATIONS OPERATION MAINTENANCE REMOVING THE FRONT WHEEL Set a stand or a block under the engine and see that the front wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork stanchions Hold the head of the wheel axle 2 in place unscrew the bolt 3 on the opposite side draw the wheel axle out NOTES Do not operate the front brake lever when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top 5 OPERATION MAINTENANCE EN 35 BERE REASSEMBLING THE FRONT WHEEL Fit the L H spacer A on the wheel hub Fit the wheel between the front fork legs so that the brake disc is fitted into the caliper Fit the wheel axle 2 from the R H side after greasing it and push it to the stop on the L H leg during this operation the wheel should turned Tighten the screw 3 on the fork side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on t
27. e case then loosen lock nut 3 and loosen or tighten screw 4 to respectively increase or decrease the play WARNING Operation with damaged throt tle cable could result in an unsafe riding con dition IDLE ADJUSTMENT Idling should be adjusted only when the engine is hot and throt tle is closed as follows turn the idle speed adjuster screw 1 until setting 1500 RPM 100 turn clockwise to increase the speed and counter clock wise to reduce the speed WARNING Exhaust gas contains poisonous carbon monoxide gas Never run the engine in a closed area or in a confined area EN 22 SPECIFICATIONS OPERATION MAINTENANCE ADJUSTMENT OF THE CLUTCH CONTROL LEVER To adjust the clutch control lever you will need to adjust cable tension using the adjuster on the lever Shift the rubber protection 1 Work on the adjuster screw 2 turn it in the direction indi cated by the arrow A to decrease clearance turn it in the direction indicated by the arrow B to increase it There should be at least 10 mm 0 39 in free play V before the clutch begins to disengage The adjustment can be also effected with tightener 3 set on the left of the frame Take care to tighten properly the lock nut If the clutch slips under load or drags in disengaged position after play has been adjusted it must be taken apart for inspection 3 Adjusting screw 4 Locknut 5 Rubber cap SPARK CONTRO
28. e for about 5 minutes to warm the oil then drain the oil Put in fresh transmission oil Check all the points listed under the inspection and Adjustment Section Appendix A Lubricate the points listed in the Lubrication Section Appendix A EN 44 SPECIFICATIONS OPERATION MAINTENANCE T CLEANING IMPORTANT RECOMMENDATION Premised that before the motorcycle washing it is necessary to protect opportunely from the water the following parts a Rear opening of the muffler b Clutch and brake levers hand grips handlebar commuto tors c Air cleaner intake d Fork head wheel bearings e Rear suspension links AAN DN IH 001 SPECIFICATIONS OPERATION MAINTENANCE EN 45 BENE it is necessary ABSOLUTELY TO AVOID THAT HIGH PRESSURE JETS OF WATER OR AIR come to contact with THE ELECTRICAL PARTS espe cially the electronic control unit 1 and the dashboard 2 AA After washing Lubricate the points listed in the Maintenance Table Appendix A Start the engine and run it for 5 minutes Test the brakes before riding the motorcycle WARNING Never wax or lubricate the brake disc Loss of braking and an accident could result Clean the disc with an oilless solvent such ans acetone Observe the solvent warn ings A MN hes e A L 44 EN 46 SPECIFICATIONS OPERATION MAINTENANCE After each clean
29. eturn to its central position before another gear change can be made Neutral position N is between first low and second gears First gear is engaged by pushing the lever downwards all the other gears are engaged by pushing the lever upwards The position of the gear shift lever on the shaft can be varied by loosening screw pulling lever out placing lever in new position on the shaft when the operation is over tighten the screw and then tightening the screw CAUTION Do not shift gears without disen gaging the clutch and closing the throttle The engine could be damaged by overspeed and shock WARNING Do not downshift when traveling at a speed that would force the engine to overrev in the next lower gear or cause the rear wheel to lose traction N Neutral KICKSTART PEDAL The kickstart pedal 2 is situated on the right hand side of the motorcycle EN 16 SPECIFICATIONS OPERATION MAINTENANCE PEP ib iii bib bib Piri bib irri br rb ribs RIDING BEFORE EVERY RIDE MAKE FOLLOWING CHECKS WARNING Before each ride to prevent accidents or failures during ride make sure to go through following list 1 Check all fluids A Transmission oil level B fuel level C coolant level Make sure all caps are properly adjusted WARNING Don t remove radiator cap when hot 2 Check all controls A Throttle handgrip B Clutch lever Make sure cables are not damaged and turn smoothly Chec
30. everse the operation in order to obtain a harder action b EXTENSION CR LOWER REGISTER WR UPPER REGISTER Standard calibration 13 clicks CR Standard calibration 10 clicks WR To reset standard calibration turn register C clockwise to reach the position of fully closed then turn back by the mentioned dicks To obtain a smoother braking action turn the register anticlockwise Reverse the operation in order to obtain a harder action c AIR VENT to carry out after each competition or monthly Set the motorcycle on a central stand and release the fork fully and loosen the air vent valve D Once this operation is over tighten the valve WARNING Never force the adjusting screws beyond the maximum opening and closure positions OIL FORK LEVEL For the regular fork operation both legs must be provided with the necessary oil quantity OIL QUANTITY IN EACH FORK LEG CR 556 cm 33 93 in Cartridge 196 cm 11 96 in Fork sleeve 360 cm 21 97 in WR 643 cm WR Remove the fork legs from the fork to check the oil level Work as follows remove the damper rod caps remove springs from the legs letting the oil drain into the legs bring fork to stroke end check that level is at the distance A of 140 mm 5 51 in from rod upper limit NOTE Always replace both the spring and the spacers to keep the preload value unchanged ELELEEEEEELELELLEELLTL TEL EE EE EE ER
31. forward the headlamp carrier B and pull it towards the high in order to uncouple from the two lower supports remove the headlamp carrier remove the two filaments bulb connector 2 and the boot 3 release the bulb holder clips 4 and take out bulb 5 To replace the parking light bulb 6 extract it from the inside cover After replacement reverse operations for reassembly TAIL LIGHT WR The tail light 1 is a LED light Replace it when it does not func tion REPLACING THE NUMBER PLATE LAMP WR loosen screw 1 and remove the number plate bulb 2 from the mudguard fake bulb holder 3 and bulb 4 out of the support pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassemble ADJUSTMENT OF HEADLIGHT WR When checking the proper orienting of headlight inflate tires at right pressure sat a person on the saddle and place the mo torcycle perpendicular with its longitudinal axis 10 meter 33 ft from a wall or screen Then trace an horizontal line equal to the height of headlight center and a vertical one in line with its longitudinal axis If possibile execute this operation in a shadowy place When the low beam is on the upper boundary limit between dark and lit zone should be 9 10 th of headlight center from groud Adjust the preadlamp aiming by turning screw 1 to lower or lift the high beam A
32. from 0 00 to 99 59 59 the data will be lost with voltage lower than 6V To activate the function STP 1 push the knob SCROLL A for more than 3 seconds 151 step function ON 2nd step stop to the counters 3rd step STP 1 zero setting TRIP 1 and AVS 1 data zero setting 4th step function ON 5th step stop to the counters and so following SPECIFICATIONS OPERATION MAINTENANCE EN 13 BEBE THROTTLE CONTROL The throttle knob 1 is located on the right hand side of the handlebar The position of the throttle control can be adjusted by loosening the two fastenig screws A CAUTION Do not forget to tighten the screws A after the adjustment FRONT BRAKE CONTROL The brake control lever 2 is located on the right hand side of the handlebar The position of the throttle control can be ad justed by loosening the two fastenig screws B CAUTION Do not forget to tighten the screws B after the adjustment STEERING LOCK WR The motorcycle is equipped with a steering lock 1 on the R H side of the steering head tube To lock it procede as follows turn the handlebar leftwards place the key in lock and turn counterclockwise Push the key inwards if necessary turn to and from Turn the key clockwise and remove it from the lock To unlock the steering lock reverse the above procedure EN 14 SPECIFICATIONS OPERATION MAINTENANCE HANDLEBAR COMMUTAT
33. have a harder compression and expecially harder extension adjustment Work on the spring preload to lower the motorcycle rear side MUDDY GROUND Fork have a harder compression adjustment or replace the standard spring with a harder one Shock absorber have a harder compression and extension ad justments or replace the standard spring with a harder one Work on the spring preload to lift the motorcycle rear side We advise replacing the springs of both suspensions to compen sate the weight increase due fo the piling of the mud NOTE When the fork results as either too soft or too hard for any ad justment conditions check the oil level inside the forkrod The level can either be too low or too high Remember that too much oil inside the fork will involve a more frequent air drain age When the suspensions do not react to the changes of cali bration check that the adjusting units are not blocked EN 28 SPECIFICATIONS OPERATION MAINTENANCE The standard calibrations and the adjustment procedures are shown below ADJUSTING THE COMPRESSION FORK a COMPRESSION CR UPPER REGISTER WR LOWER REGISTER Standard calibration 9 clicks CR Standard calibration 10 clicks WR Remove plug B and turn register A clockwise until the posi tion of fully closed is reached then turn back by the mentioned dicks To obtain a smoother braking action turn the register anticlockwise R
34. he L H side 51 45 Nm 5 25 Kgm 38 the screws 1 on the L H leg 10 4 Nm 1 05 Kgm 7 7 ft lb Check that the brake disc slides between the caliper pads with out any friction NOTE After reassembly pump the brake control lever until the pads are against the brake disc REMOVING THE REAR WHEEL Unscrew the nut 1 of the wheel pin 3 and extract it It is not necessary to unloose the chain adjusters 2 in this way the chain tension will remain unchanged after the reassembly Extract the complete rear wheel by taking care of the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the disc into the caliper Ce 270 770 DEN NOTES Do not operate the rear brake pedal when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top After reassembly pump the brake control pedal until the pads are against the brake disc Tightening torque figures 1 142 1 Nm 14 5 104 8 ft lb PIPE ETP EP TEEPE PEPE EL EEE LEE HE EEE EEE EEE SPECIFICATIONS OPERATION MAINTENANCE 37 BEBE TIRES BRAKES 4 Front brake caliper Care should be taken to keep the tyres properly inflated See mayor components are brake master cylinder with its lever 5 Front brake disc Technical data chart at the beginning of the manual for cor front or pedal rear brakeline caliper assembly
35. il you have re ceived expert instruction and are in excellent physical condition PRECAUTIONS FOR CHILDREN WARNING Park the vehicle where it is unlikely to be bumped into or damaged Even slight or involuntary bumps can cause the vehicle to topple over with subsequent risk of serious harm to people or children To prevent the vehicde from tipping over never park it on soft or uneven ground nor on asphalt strongly heated by the sun Engine and exhaust pipes become very hot during riding Always park your where people or children an not easily reach these parts in order to avoid serious burns EN 4 SPECIFICATIONS OPERATION MAINTENANCE IDENTIFICATION DATA The engine number is printed on the upper side of the engine case whereas the frame number is printed on the steering tube Always state the number stamped on the frame and write it on this booklet when placing orders for spare parts or when asking for informations about your motorcicle FRAME NUMBER TT VEHICLE IDENTIFICATION NUMBER V I N The full 17 digit serial or Vehicle Identification Number is stamped on the steering tube R H side Model designation A Model Year 2013 Progressive no ZKH 4H00AA DV 050001 e 9 CR 125 USA ZKH CR123 000000 dM e A 4 ZKH WR123 DV 000000 m e A 9 4HOOAA DV
36. ing it is recommended the use of a water repellent product suitable for electrical contacts see table for lubrications and supplies on all the electrical contacts without disconnect them _ 1 t ii A x _ PRE DELIVERY INSPECTION Description Operation Pre delivery Description Operation Pre delivery a Engine oil Check level J Tyres Check pressure J Two stroke mix oil level Check level BL Side stand Check operation J Coolant Check Restore level J Side stand switch Check operation J Cooling system Check for leakage J Electrical equipment Check operation J Electric fans Check operation BLA Instrument panel Check operation J Spark plugs Check Replace Lights Visual signals Check operation J Throttle body Carburettor Check and adjust J Horn Check operation J Brakes Clutch fluid Check level J Headlight Check operation J Brakes Clutch Check operation J Ignition switch Check operation Brakes Clutch Check lines for leakage J Locks Check operation J Throttle control Check operation J Screws and nuts Check Tighten J Throttle control Check Adjust play J Hose clamps Check Tighten Choke control Check operation J General lubrication E Flexible controls and transm Check Adjust J General test J Drive chain Check Adjust J only for motorcycles with 2 stroke engine only for some models 008 SPECIFICATIONS OPERATION MAINTENANCE EN 47 BEBE ALPHABETIC INDEX Page
37. it by loosening the six fastening screws to the hub WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Note In muddy and wet onditions mud sticks to the chain and sprockets resulting in an overtight chain The pinion the chain and the rear sprocket wheel wear increases when running on muddy ground Normal consumption Excessive consumption O LUBRICATING THE CHAIN Lubricate the chain following these instructions WARNING Never use grease to lubricate the chain Grease helps to accumulate dust and mud which act as abrasive and hepl to rapidly wear out the chain the sprocket and the crown Disassembling and cleaning When particularly dirty remove and clean the chain before lubrication Work as follows Set a stand or a block under the engine and see that the rear wheel is lifted from the ground Remove screws 1 transmission sprocket guard 2 clip 3 master link 4 and transmission chain 5 To reassemble reverse the above procedure SPECIFICATIONS OPERATION MAINTENANCE EN 33 2 Check that the chain is neither worn out nor damaged If the rollers or the links are damaged replace the chain by fol lowing the instructions given in the Periodical Maintenance Table 3 Check that neither the sprocket nor the crown are damaged 4 Wash and clean the chain as described hereunder Washing the chain without
38. k brakes Look for brake fluid leaks and worn hoses Check for proper functioning Check suspensions Compress fork and rear suspensions Look for oil leaks and ensure proper functioning Check wheels Check spokes and look for worn bearings Check rims and tyres Check tyre pressure Check chain rollers and sprockets Check wear on chain rollers and sprockets Ensure chain is correctly adjusted and lubricated Check air filter and intake system Check that air filter is clean Check all rubber connections and clamps e A4 8 Check exhaust system Check hook up look for cracks Check muffler 9 Check torque A Spark plug B General check of torque 10 Check steering action Check bearing play 11 Check the electric system WR Start the engine and check that the front and rear lamps the stop light the turn signals the cluster warning lights and the horn are working correctly WARNING Failure to perform these checks every day before you ride may result in se rous damage or a severe accident RUNNING IN To obtain the best settling of the engine moving elements for driving your motorcycle to the best of your capability run in the engine for several hours following these procedures 1 FROM STOP POSITION Start the engine and run at idle but open the throttle periodically and briefly until the engine is thor oughly warmed up Within 3 4 minutes the coolant temperature will have reached ap
39. n pump reservoir must never be below the minimum value 1 which can be checked from the window on the rear side of the pump body A decrease of the fuel level will let air into the sustem hence an extension of the level stroke WARNING If the brake lever feels mushy when it is applied there may be air in the brake lines or the brake may be defective Since it is dangerous to operate the motorcyde under such conditions have the brake checked immediately by an authorized HUSQVARNA dealer BRE EN 26 SPECIFICATIONS OPERATION MAINTENANCE CAUTION Do not spill brake fluid on to any painted surface or lenses CAUTION Do not mix two brands of fluid Change the brake fluid in the brake line if you wish to switch to another fluid brand CAUTION Brake fluid may cause irritation Avoid contact with skin or eyes In case of contad flush thoroughly with water and call a doctor if your eyes were exposed A to encrease clearance B to decrease clearance REAR BRAKE PEDAL POSITION ADJUSTMENT The position of the rear foot brake pedal as to the footrest may be adjusted according to the individual needs For the adjusting proceed as follows loosen the screw 1 turn the cam 2 in order to adjust the brake pedal idle stroke A the operation done tighten the screw 1 The adjusting operation carried out adjust the idle stroke of the pedal as follows REAR BRAKE IDLE STROKE ADJUSTMENT
40. nce CR 12 79 in 325 mm Minimum ground clearance WR 124 in 315 mm Kerb m without fuel CR 202 8 16 92 kg Kerb weight without fuel WR 211 6 Ib 96 kg Fuel tank capacity 1 32 Imp quarts 1 59 U S quart 1 5 reserve included 1 54 Imp gall 1 85 U S zr Coolant 0 97 1 14 Imp Quarts 1 16 1 37 U S Quarts Transmission 0 70 Imp Quarts 0 85 U S Quarts I TELE LEE EE ETE UE EEE 5 1 5 OPERATION MAINTENANCE TABLE FOR LUBRICATION SUPPLIES Engine lubricating oil CASTROL A747 Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 10W 40 Engine coolant CASTROL MOTORCYCLE COOLANT Brake system fluid CASTROL RESPONSE SUPER DOT 4 Grease lubrication CASTROL PASTE TA GREASE Final drive chain lubrication CASTROL CHAIN LUBE RACING Front fork oil Kayaba KHL15 11 Oil for rear shock absorber CASTROL SYNTHETIC FORK OIL 5W Electric contact protection CASTROL METAL PARTS CLEANER CASTROL MOTORCYCLE DWF Fillers for radiator AREXONS TURAFALLE LIQUIDO EN 9 CONTROLS CR WR USA Fuel cock The cock is screw type and is on the left of the tank loosen by turning ring nut 1 to open tighten to close CR WR USA lt gt NES WR Fuel cock The cock
41. ng in NOT LESS than 3 1 33 when running in is over Primary drive transmission Gearbox by the oil contained in the crankcase IGNITION electronic digital capacitor discharge type with pr advance Spark plug type QN B4 NGK BROEG Dp CH 0 0236 in 0 6 mm EN 8 SPECIFICATIONS OPERATION MAINTENANCE FUEL SYSTEM Carburettor Mikuni TMX 38 Venturi 1 5 in 38 mm High speed jet 460 300 Low speed jet 35 Low speed jet 15 80 Starting jet 50 Main R 8 914 RE RR g 6 1 Throttle piston 40 Throttle piston 5 0 6BFY43 Metering pin slot 3rd Metering pin slot 2nd Idle mixture adjusting screw CR rounds 1 1 4 Idle mixture adjusting screw WR rounds 1 1 2 PRIMARY DRIVE Drive pinion gear Clutch ring gear
42. of liquid in the radiator warm up the motor in order to eliminate any possible air bub ble fit the motor in vertical position and check that the liquid in the radiators must be 10 mm 0 4 in over the radiant mas if not top it up screw the R H radiator plug WARNING Coolant on tires will make them slippery and an cause an accident or injury Periodically check the connecting hoses see Periodical mainte a nance card this will avoid coolant leakages and consequent engine seizure If hoses show cracks swelling or hardenings due to sheats desiccation their replacement shall be advisable Check the correct tightening of the clamps Fia a gt LEELEEEEEEEEEEE EE EE EEUU SPECIFICATIONS OPERATION MAINTENANCE EN 2 BEBE THROTTLE CABLE ADJUSTMENT The throttle cable can be adjusted using the screw set on the throttle or using the adjusting screw set on the carburettor cover To check for proper adjustment of throttle cable proceed as follows remove rubber cap move transmission sheath to and fro to ensure a play of ap prox mm should play be greater than 1 mm loosen lock nut 1 and register 2 should play less than 1 mm then tighten lock nut and register if register 2 should not provide sufficient movement to allow for correct adjustment then adjust register placed on carbure tor There should be approx 1 mm play on latter register should this not be th
43. ot attempt to start this motorcycle unless you are wearing high top heavy sided rid ing boots You could seriously hurt you leg if the kickstarter kicked back and your foot slipped 2 EREE EN 18 SPECIFICATIONS OPERATION MAINTENANCE STOPPING THE MOTORCYCLE AND THE ENGINE lose the throttle 1 completely so that the engine will help slow down the motorcycle For normal braking gradually apply both front and rear brakes while down shifting for maximum deceleration apply the front and rear brakes firmly When stopped pull the clutch lever and shift gear lever 2 in neutral position Press the engine stop button 3 Close the fuel cock 4 When the bike is off place it on its side stand CR WR USA TRANSMISSION OIL LEVEL CHECKING A Transmission oil level Keeping the motorbike level and in a vertical position check the oil a through the inspection 1 window on the right crankcase Check if level lolis about midway of the inspec tion porthole To fi up remove the filler cap 2 Note Have this operation made with warmed up engine WARNING Be careful not to touch hot engine oil CHANGING TRANSMISSION GEARBOX OIL Remove the engine guard 1 by loosening the lower screws 2 and the side screws 3 NOTE On reassembly make sure the spacer 4 is correctly positioned To change oil unscrew the undersump cap 5 remove the cap 6 and let the
44. proximately 60 1405 Do not ride the motorcycle 2 Stop the engine and let it cool down naturally until its tem perature is equal to the ambient air temperature This will allow the piston to align itself to any imperfections which might exist at the cylinder wall a 3 Repeat steps 1 and 2 Do not ride the motorcycle 4 Bring the engine up to normal running temperature Ride the motorcycle approximately 10 minutes at moderate speeds Then repeat cool down procedure AVOID HARD ACCELERATIONS 5 Bring engine up to normal temperature Ride motorcycle approximately 15 minutes at moderate to high speeds Again avoid hard accelerations 6 Repeat cool down procedure 7 Full throttle operation must be avoided until the engine has reached operating temperature even after the break in process is completed When the above procedure is followed correctly engine durability and performance will be greatly enhanced CHECKS WHILE RUNNING IN When running in the following should be checked out WHEELS SPOKES TENSION TIGHTENING OF WHEELS FORK PIN TIGHTENING CHAIN ADJUSTMENT STEERING BEARING PLAY HANDLEBAR TIGHTENING ENGINE GRIP TO FRAME SUCTION FITTING GRIP HEAD AND CYLINDER NUTS GRIP Note After break in install a new spark plug and change the transmission oil After running in check that vehicle nuts and bolts are properly tightened SPECIFICATIONS OPERATION MAINTENANCE EN
45. r anteed exempt from functional defects and covered with legal guarantee if the STANDARD CONFIGURATION is maintained and the suggested maintenance table shown on Appendix A is observed If WR vehicles are transformed in COMPETITION MOTORCYCLES with FULL POWER ENGINE the suggested maintenance table for competition use is shown on Ap pendix A TL TEEPE EEE 5 1 5 OPERATION MAINTENANCE EN 3 BEEN IMPORTANT The reference for recognition of the guarantee will be the MO TORCYCLE CONFIGURATION as shown below A STANDARD MOTORCYCLE STREET LEGAL with LIMITED POWER ENGINE B COMPETITION MOTORCYCLE RACING USE with FULL POWER ENGINE This motorcycles was not designed for long trips with the engine always at maximum rpm as can occur whilst travelling on roads or highways Long trips at full throttle can cause severe damage fo the engine This motorcycles is setup for competition use and therefore guarantees maximum formance with the rider alone It is thereby not recommended to use the vehicle on cir cuits or off road with a passenger ALWAYS keep in mind that these motorcycles have been designed strictly for competition use that is for conditions of usage very different from those presented on the road ALWAYS keep in mind that these motorcycles have been designed strictly for competition use that is for conditions of usage very dif ferent from those presented on the ro
46. ssemble side panel and saddle oo N Un gt 6 WARNING Be careful not to touch hot ex haust pipe while adjusting the shock abosr ber SHOCK ABSORBER DAMPING ADJUSTMENT Adjustment of the compression stroke is independent from the rebound stroke A COMPRESSION Standard calibration 1 Low damping speed 15 clicks 2 clicks register 4 3 High damping speed 15 clicks 2 clicks register 6 To reset the standard calibration turn upper registers 1 and 3 clockwise until reaching fully closed position Return then back for the mentioned clicks In order to obtain a smooth braking action turn the registers anticlockwise Reverse a the operation in order to obtain a harder braking action B EXTENSION Standard calibration 18 clicks 2 clicks To reset the standard calibration turn lower register 2 clock wise until reaching fully closed position Return then back for the mentioned clicks In order to obtain a smooth braking action turn the register anticlockwise Reverse the operation in order to obtain a harder braking action ELELEEEEEELELLLEELELTL TELLE LEE EE EE EE OE EHE IE SPECIFICATIONS OPERATION MAINTENANCE EN 3 BENE CHAIN ADJUSTMENT Fig A Chain should be checked adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear If the chains becomes badly worn or is poorly adjusted i e if it is too loose or too
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