Husqvarna CR 65 2012 Page 22 Workshop Manual Download

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C.4

CR 65 2012

TROUBLESHOOTING

Workshop Manual Ed. 09-2011

CHASSIS

Trouble

Cause

Remedy

The handlebar is hard to turn

1. Tyre pressure insufficient

Inflate

2. Bearing adjuster ring nut or steering stem nut overtightened Adjust

3. Bent steering stem

Replace bottom yoke

4. Worn or seized steering bearings

Replace

The handlebar vibrates

1. Bent fork legs

Replace

2. Bent front wheel axle

Replace

3. Bent/broken chassis

Replace

4. Bent front wheel rim

Replace

5. Worn front wheel bearings

Replace

Shock absorption is

1. Exceeding oil quantity in fork legs

Drain the exceeding oil

too hard

2. Fork oil viscosity too high

Change

3. Overinflated tyres

Deflate

4. Improperly set rear shock absorber

Adjust

Shock absorption is

1. Insufficient oil quantity in fork legs

Top up

too soft

2. Fork oil viscosity too low

Change

3. Weak fork springs

Replace

4. Weak rear shock absorber spring

Replace

5. Improperly set rear shock absorber

Adjust

Wheel (front and

1. Bent wheel rim

Replace

rear) vibrates

2. Worn wheel hub bearings

Replace

3. Incorrect spoke tension

Adjust

4. Wheel axle nut loose

Tighten

5. Worn rear swinging arm bearings

Replace

6. Improperly adjusted chain tensioners

Adjust

7. Improperly balanced wheel

Balance

Rear suspension is

1. Shock absorber worn ball joints

Replace

noisy

2. Faulty shock absorber

Replace

Insufficient braking

1. Air presence in braking system circuit

Bleed

(front and rear)

2. Insufficient fluid in tank

Top up

3. Worn brake pad and/or disc

Replace

4. Damaged disc

Replace

5. Improperly adjusted brake pedal

Adjust

6. Water in brake system

Change fluid

Summary of Contents for CR 65 2012

Page 1: ...CR 65 2012 Workshop Manual Ed 09 2011 ...

Page 2: ... any errors or omissions in this manual and reserves the right to make changes to reflect ongoing product development Illustrations in the ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st Edition 09 2011 ...

Page 3: ...TENTS 1st Edition 09 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 CR 65 2012 ...

Page 4: ...learly 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 specific 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...

Page 5: ...B Troubleshooting C Settings and Adjustments D General Procedures E Engine Disassembly F Engine Overhaul G Engine Reassembly H Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N Hydraulically Controlled Clutch P Fuel supply S Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications apply to all models ...

Page 6: ......

Page 7: ...b 1 CR 65 2012 b Workshop Manual Ed 09 2011 IMPORTANT NOTICES Section ...

Page 8: ...quired maintenance inspections carried out at authorised HUSQVARNA dealers The Customer bears all part replacement and labour costs needed to respect the maintenance schedule In case of motorcycle hire the warranty becomes NULL and VOID 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...

Page 9: ...A 1 CR 65 2012 A Workshop Manual Ed 09 2011 GENERAL INFORMATION Section ...

Page 10: ...uel system A 3 Lubrication A 3 Cooling A 3 Ignition system A 3 Kick A 3 Primary drive A 3 Gearbox A 3 Secondary drive A 3 Drive chain A 3 Chassis A 3 Suspension A 3 Brakes A 4 Wheels A 4 Tyres A 4 Overall dimensions Weight A 4 Electrical components location A 5 Capacities A 5 ...

Page 11: ...ransmission ratio 3 26 Gearbox Type constant mesh gear type Transmission ratio 1st gear 2 846 z 37 13 2nd gear 2 125 z 34 16 3rd gear 1 722 z 31 18 4th gear 1 428 z 30 21 5th gear 1 217 z 28 23 6th gear 1 083 z 26 24 Secondary drive Transmission sprocket Z 14 Rear sprocket Z 48 Transmission ratio 3 43 Drive chain Make and type D I D 420 1 2 x 1 4 Chassis Type single frame in steel tubes with recta...

Page 12: ...ulic control and four piston fixed calliper Rear Type with fixed disc Wave type Ø 165 mm with hydraulic control and two piston fixed calliper Wheels Rims Front in light alloy 1 6x14 Rear in light alloy 1 6x12 Tyres Front PIRELLI SCORPION MX60 100 14 29M NHS Rear PIRELLI SCORPION MX80 100 12 50M NHS Cold tyre pressure Front 0 8 bar Rear 0 8 bar Overall dimensions Weight Kerb weight without fuel 56 ...

Page 13: ...RACING 10W 50 500 cc oil change Front fork oil CASTROL SYNTHETIC FORK OIL 5W Cooling system fluid CASTROL MOTORCYCLE COOLANT 0 6 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 Clutch fluid MINERAL OIL SAE 10 FOR HYDRAULIC CIRCUITS Drive chain lubrication CASTROL CHAIN LUBE RACING Grease lubrication CASTROL LM GREASE 2 Electric contact protection...

Page 14: ......

Page 15: ...B 1 CR 65 2012 B Workshop Manual Ed 09 2011 MAINTENANCE Section ...

Page 16: ...eck Idle adjustment warm engine Breather pipes conditions and position without bends check Reed valve reed check Clutch plates wear check Clutch hub screw tightening check Clutch spring length check Cooling system leakage check Cylinder and piston wear check Drive shaft axes misalignment check Connecting rod big end bearing radial clearance check Connecting rod small end bearing radial clearance c...

Page 17: ...heck Front lever and brake pedal adjustment and operation check Braking system screw tightening check Exhaust system check Control cable lubrication and free sliding check Air filter and filter box cleaning Shock absorber and fork operation check Swinging arm support check Steering bearing check and or adjustment Screw tightening check Fork dust seal removal and cleaning Rim runout and spoke tensi...

Page 18: ...ransmission oil level check Coolant level check Brake fluid level check Brake shoe wear check Brake operation check Control cable adjustment and lubrication Chain cleaning lubrication and tension check Air filter and filter box cleaning Tyre pressure and wear check Screw nut and tie correct tightening check Fuel pipe status check ...

Page 19: ...C 1 CR 65 2012 C Workshop Manual Ed 09 2011 TROUBLESHOOTING Section ...

Page 20: ...fuel 1 Tank cap breather clogged Clean 2 Fuel cock clogged Clean 3 Fuel feed pipe clogged Clean 4 Floater valve or floaters faulty Replace 5 Linkage is blocking floater valve Release Carburettor floods 1 High fuel level in bowl Adjust 2 Floater valve or floaters worn or stuck open Replace or release The engine stops 1 Dirty spark plug Clean easily 2 Carburettor jets clogged Clean 3 Low idle Adjust...

Page 21: ...oken selector return spring Replace 2 Worn shifter forks Replace The gears are disengaged 1 Worn sliding gear engagements Replace 2 Worn gear grooves Replace 3 Worn dog slots in gears Replace 4 Worn selector shaft splines Replace 5 Damaged shifter fork shafts Replace Engine power lack 1 Dirty air filter Clean 2 Carburettor main jet clogged or Wrong size Clean or replace 3 Poor fuel quality Replace...

Page 22: ...sorber Adjust Shock absorption is 1 Insufficient oil quantity in fork legs Top up too soft 2 Fork oil viscosity too low Change 3 Weak fork springs Replace 4 Weak rear shock absorber spring Replace 5 Improperly set rear shock absorber Adjust Wheel front and 1 Bent wheel rim Replace rear vibrates 2 Worn wheel hub bearings Replace 3 Incorrect spoke tension Adjust 4 Wheel axle nut loose Tighten 5 Worn...

Page 23: ...or easily 2 Dirty air filter Clean 3 Worn piston rings Replace 4 Worn piston or cylinder liner Replace 5 Spark plug featuring a too high heat rating Replace with recommended spark plug Spark plug electrodes 1 Mixture too lean Adjust carburettor overheat 2 Spark plug electrode gap too close Adjust 3 Spark plug featuring a too low heat rating Replace with recommended spark plug ...

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Page 25: ...D 1 CR 65 2012 D Workshop Manual Ed 09 2011 SETTINGS AND ADJUSTMENTS Section ...

Page 26: ...D 10 Oil level check D 11 Oil replacement D 11 Coolant level check D 12 Coolant replacement D 12 Air filter cleaning and check D 13 Chain adjustment D 14 Chain lubrication D 14 Removal and cleaning D 14 Chain cleaning D 14 Chain lubrication D 14 Fork adjustment D 15 Rebound damping adjustment RH fork leg D 15 Compression damping adjustment LH fork leg D 15 Fork position adjustment D 16 Rear shock ...

Page 27: ...D 3 CR 65 2012 Workshop Manual Ed 09 2011 SETTINGS AND ADJUSTMENTS CR 65 ...

Page 28: ...ank removal Remove the saddle as described in the relevant paragraph Close the fuel cock 2 and loosen the clamp 3 on the hose running to the carburettor Detach hose 4 from carburettor making sure to drain any fuel in the hose into a container Remove the side panels as described in section E Slide the breather hose 7 out of the steering tube Remove the retaining screw 8 and then the tank 9 ...

Page 29: ...istgrip 1 and make sure it has about 2 mm free play If not so move the rubber protection 2 loosen the ring nut 3 and work the adjuster screw 4 loosen to decrease play or tighten to increase it After the adjustment lock the ring nut 3 and fit the rubber protection 2 again After the adjustment check for no rpm increase when turning the han dlebar to the left and to the right with engine running at i...

Page 30: ... suitable idle speed setting Idle adjustment Adjust the carburettor with warm engine and with the throttle control in closed position Proceed as follows Turn the idle speed adjuster screw 1 located on the left hand side of the vehicle until setting idle RPM as required turn clockwise to increase the speed and counter clockwise to reduce it Front brake fluid level check Check the front brake fluid ...

Page 31: ...sh thoroughly with water and contact a doctor if your eyes were exposed Clutch fluid level check Check the clutch fluid level as follows Stand the minicross level and upright Loosen the screws 1 and remove cover 2 together with diaphragm 3 Make sure the oil level is about 3 mm from the top edge in case top up with oil of the type specified in the LUBRICATION AND SUPPLIES table If the clutch feels ...

Page 32: ...gain Lever distance adjustment To adjust the distance between the lever 1 and the throttle twistgrip work on the ring nut 3 by turning it clockwise A to decrease it and counterclockwise B to increase it Clutch lever adjustment Lever distance adjustment To adjust the distance between the clutch lever 1 and the throttle twistgrip work on knob 3 by turning it clockwise A to increase it and counterclo...

Page 33: ...play of the pedal following the instructions provided in paragraph Rear brake pedal free play adjustment Rear brake pedal free play adjustment The rear brake pedal 3 should have a free play B 5 mm before the brakes begin to bite Should this not happen operate as follows loosen nut 4 operate the pump rod 5 to increase or decrease the free play tighten nut 4 at the end of the operation When the free...

Page 34: ...xtension of the lever stroke If the brake pedal feels mushy when pulled there may be air in the brake line or the brake may be defective CHECKTHE BRAKING SYSTEM see Section L Too much brake lever free play may reduce braking action CHECK BRAKE PAD THICKNESS see Section L Do not spill brake fluid onto any painted surface or lens for example lights lens Do not mix two brands of fluid Completely chan...

Page 35: ... If the oil level is low top up through the dedicated oil hole 2 located on the casing upper side Oil replacement Be careful not to touch hot engine oil Drain the oil with WARM ENGINE proceed as follows Remove the oil filler cap 2 Put a drip pan under engine Remove oil drainage plug 3 Evacuate the exhausted oil Refit the drainage plug 3 15 Nm 1 5 Kgm 11 06 ft lb Top up with suitable quantity throu...

Page 36: ...es may arise in eliminating coolant from painted surfaces If this occurs wash off with water Coolant replacement Place a vessel on the RH side of the cylinder under the screw 1 SLOWLY open the RH radiator cap 2 slope the motorcycle on the left side to drain the coolant easily in the vessel Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any poss...

Page 37: ...products then soak it in the specific oil Use a cloth to clean the filter box internal side 5 Reassemble all parts in the reverse order compared to disassembly Never tamper the filter box cover we strongly recommend not to remove the material delimited by the cut to increase the air flow because this would lead to a drastic decrease of performances at low and medium rpm against a very little impro...

Page 38: ... guide Adjust the chain tension so that the drill rod passes freely without excessively loosening the chain If it is not proceed as follows Loosen the hexagon nut 1 Loosen the check nuts 2 on both sides Work on screw 3 on rear swinging arm both sides to increase or decrease the chain tension having care to centre the wheel in the rear swinging arm referring to the notches on the swinging arm When ...

Page 39: ...chain as described hereunder Chain cleaning Wash using petroleum or naphtha If you use fuel or especially trichloroethylene dry and lubricate the chain to avoid oxidisation Chain lubrication After drying dip the chain in Molybdenum Disulphide chain lubricant if possible or in warm high viscosity engine oil if warmed up oil will be more fluid Fork adjustment The fork RH and LH legs can be adjusted ...

Page 40: ... the rider weight and the road conditions It is possible to adjust the shock absorber acting on the spring pre load according to the rider weight The shock absorber adjustment affects both the stability and the handlingofthemotorcycle Afterchangingthestandardsuspension setting ride with care Before making any change we recommend to identify a reference dimension A with bike on the central stand an...

Page 41: ... chas sis 5 Turn the rear chassis upside down the reach the rear shock absorber adjust ing ring nuts 6 Clean lock ring nut 1 and adjuster ring nut 2 of the spring 3 7 Either with a hook wrench or an aluminium punch loosen the lock ring nut 8 Turn the adjuster ring nut as required 9 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 5 Nm 0 5 Kg...

Page 42: ...is possible to adjust the compression travel of the shock absorber B COMPRESSION Standard setting 1 turn and from fully closed To reset the standard setting turn upper adjuster screw clockwise 2 until reach ing fully closed position Then turn it back by the mentioned turns In order to obtain a smooth braking action turn the adjuster screw counter clockwise Vice versa to obtain a harder braking act...

Page 43: ...moothly Sit on the ground in front of the front wheel and hold the lower ends of the fork legs Push and pull in a front to rear motion to feel for play If any play is detected adjust as follows Loosen the screws 3 with a 6 mm wrench Loosen and retighten the nut 2 to a torque of 10 Nm 1 0 Kgm 7 38 ft lb Tighten the three screws 3 on the steering head to 25 Nm 2 5 Kgm 18 44 ft Lb Handlebar position ...

Page 44: ...ower clamps paying attention to the correct rout ing of wires and pipes they do not have to be twisted Place the upper U bolts 1 symmetrically and pre tighten the screws 2 in a crossed pattern in order to have the same front and rear distance A between the upper and lower U bolt Once the handlebar correct inclination has been found tighten the screws 2 to a torque of 28 Nm 2 85 Kgm 20 65 ft lb Kee...

Page 45: ...and in case replace them Replace the supply pipe 1 as described in section E Exhaust system check Remove exhaust system components as described in Section E Ensure that pipe 1 and silencer 2 do not show any sign of failure or damage replace if cracked or damaged Check for any gas leakage between silencer end caps and central pipe which would indicate a wrongly carried out sealing 2 1 ...

Page 46: ...luminium protections having care not to deform the pipe Remove screws 2 that retain the rear end cap 3 and remove it from the silencer body Slide out the external pipe and remove the worn damaged sound deadening material Clean the pipe damaged by any residue of burnt material and oil using first a wire brush and a compressed air jet then Wrap the damaged pipe up in the new sound deadening material...

Page 47: ...ature resistant silicone Apply some sealant 6 on the rear end cap too and position the latter by starting the retaining screws 2 WITHOUT TIGHTENING THEM COMPLETELY Once the silencer has been reassembled remove any surplus silicone Refit the silencer as described under the relevant paragraph ONLY NOW tighten the rear end cap screws to a torque of 9 Nm ...

Page 48: ......

Page 49: ...E 1 CR 65 2012 E GENERAL PROCEDURES Workshop Manual Ed 09 2011 Section ...

Page 50: ...val E 5 Rear chassis with rear mudguard and air filter removal E 6 Exhaust system removal E 7 Fuel tank removal E 9 Carburettor removal from the engine E 10 Spark plug cap removal E 10 Radiator removal E 10 Swinging arm removal E 12 Secondary drive chain removal E 13 Clutch actuator removal E 13 Generator cable removal E 14 Engine removal from the chassis E 14 ...

Page 51: ...This section describes the operations preliminary to engine removal Please note that in order to gain access to certain motorcycle components rear shock absorber electrical parts wiring etc it may be necessary to partially remove some parts RIGHT HAND SIDE LEFT HAND SIDE ...

Page 52: ...r holder removal Loosen the screw 1 with an 8 mm wrench and lift the Number holder to remove it Widen the cable ring 2 to release the engine stop cable 4 and the front brake transmission 3 Front mudguard removal Using an 8 mm wrench loosen the four screws 1 and remove mudguard 2 ...

Page 53: ...taining screw pin Side panel removal Remove the saddle as described in the relevant paragraph To remove the side panels of the vehicle it is necessary to first remove the plastic cover 1 of the air box loosening the rear chassis retaining screw 2 Loosen the five retaining screws 3 and remove the left side panel 4 Proceed in the same way to remove the right side panel ...

Page 54: ...ring wrench screw and a 10 mm wrench nut to remove the screw and the nut to release the silencer from the rear chassis Use a 12 mm ring wrench to remove the four retaining screws 4 from the rear chassis on both sides Remove the rear chassis with relevant mudguard and air filter 5 from behind releasing the carburettor rubber fitting For reassembly follow the removal procedure in the reverse order h...

Page 55: ...to remove the screw and the nut to release the silencer 9 from the support bracket 10 it is not necessary to remove the Number holder Use an 8 mm ring wrench to release the silencer 9 from the elastic support fastened on the chassis Key 1 Expansion pipe silencer 2 Gasket 3 Springs 4 Elastic supports 8 Coupling 9 Silencer 10 Silencer support ...

Page 56: ...e the silencer 9 by sliding it from the rear side as shown in the figure Pay attention to the rubber connection coupling 8 Remove the springs 3 from the silencer 1 Use an 8 mm ring wrench to remove the screw 7 from the elastic support fastened on the chassis Remove the silencer 1 ...

Page 57: ...ning torque figures Fuel tank removal Slide the breather hose 1 out of the steering stem and loosen chassis con nection screw 2 Pay attention to the bushing under the screw head Turn the ring nut of the fuel cock 3 clockwise to shut off fuel supply and loosen the clamp 4 on the hose running to the carburettor Detach the hose at carburettor end and let fuel drain into a pan Remove the tank 5 by sli...

Page 58: ...d remove the carburettor from the intake fitting Spark plug cap removal Take off the spark plug cap 1 Radiator removal Remove the grids from the two radiators 1 releasing the pins from the holes as shown in the figure Before removing the radiator pipes empty the cooling system by loosening the screw 2 on the water pump cover ...

Page 59: ...onnection pipe make sure to keep the washer Open the clamp 5 of the RH radiator connecting lower pipe and the clamp 6 of engine head connecting pipe 7 using clic clamp pliers available on the market Remove the two screws 3 that retain the LH radiator to the chassis Remove the LH radiator with head connection pipe 7 To remove the RH radiator proceed as follows Loosen clamp 1 that fastens the connec...

Page 60: ...asten the radiator to the chassis by releasing the RH radiator and the two pipes connecting it to the LH radiator the pipe to the water pump and the breather hose on the plug Otherwise release the radiator from the two LH radiator connection pipes opening the clamps 6 with the clic clamp pliers and then disconnect it from the chassis as described above Swinging arm removal Remove the plug 1 of the...

Page 61: ...ht to remove the nut 2 of the swinging arm pivot 3 and the swinging arm A itself Secondary drive chain removal Remove the case cover 1 to access the drive chain Use needle nose pliers to remove the master link 2 and open the drive chain Clutch actuator removal Remove the whole actuator 1 removing the three screws 2 that fasten it to the clutch cover and release the pipe from the ring 3 that retain...

Page 62: ...le disconnection Cut the tie 1 that retains the cables against the chassis Disconnect the generator electric cable connector 2 Engine removal from the chassis Remove the two front screws 1 that retain the engine to the chassis Remove the engine from the vehicle left side 2 1 1 ...

Page 63: ...F 1 CR 65 2012 ENGINE DISASSEMBLY Workshop Manual Ed 09 2011 Section F ...

Page 64: ... Clutch cover removal F 5 Clutch disassembly F 5 Primary drive sprocket removal F 6 Kick start pedal shaft removal F 7 Gearbox control shaft and selector plate removal F 7 Intake flange and reed valve removal F 8 Starting system disassembly F 8 Chain sprocket removal F 9 Splitting the crankcase F 9 Gearbox control and shaft removal F 9 Process F 10 Crankshaft removal from casing F 10 ...

Page 65: ...re Remove the gearbox oil drainage screws 1 with relevant sealing ring and drain the gearbox oil Cylinder head cylinder and piston removal Loosen the spark plug Remove all cylinder head screws 2 and the head itself Remove the two O rings 3 from the cylinder grooves Remove both centring bushings 4 Loosen the two clamps 5 and remove the water pipe Remove the exhaust pipe fitting 6 and its gasket by ...

Page 66: ...e gaskets Water pump disassembly WARNING It is not necessary to disassemble the water pump to remove the clutch cover The water pump remains inside the clutch cover The water pump features a hole A where spring B is located Loosen the three screws and remove the water pump with its O rings Remove the circlip 1 and slide the water pump impeller out of the shaft WARNING If the water pump impeller is...

Page 67: ...tart pedal shaft it may remain attached to the clutch cover and the water pump shaft spring page F4 spring B Remove both centring bushings Remove the spring 2 of the starting coupling the thrust washer 3 and the thrust bearing 4 Slightly turn the starting coupling 5 counterclockwise and slide it out of the kick start pedal shaft Clutch disassembly Place the retainer 1 on the hub and loosen the hex...

Page 68: ...er from the input shaft the clutch housing the sup porting bushing 3 and the thrust washer 4 placed behind Remove the starting idle gear 5 Primary drive sprocket removal Place the retaining tool 6 for the primary drive sprocket and loosen the hexagon nut TO LOOSENTHEHEXAGONNUTOFTHEPRIMARYDRIVE SPROCK ET THE PRIMARY DRIVE MUST NOT BE BLOCKED WITH A SECTOR GEAR OR ALIKE THAT WOULD DAMAGE THE CRANKSH...

Page 69: ...e 2 Remove the kick start pedal shaft from the casing Gearbox control shaft and selector plate removal Use a screwdriver to push back the sliding plate 3 and at the same time slide the gearbox control shaft out of the crankshaft Remove the screw 4 and slide the selector plate out of the selector drum Remove the circlip 5 the selector lever and spring ...

Page 70: ...ly Loosen the 3 screws of the ignition cover and remove the latter 1 Hold the rotor and using the suitable wrench remove the flanged nut with its elastic washer Screw the special puller 2 onto the rotor keep the puller and by holding the extraction screw slide the rotor out of the crankshaft Loosen the three screws 3 of the stator and remove the latter 4 Remove the engine wiring ring from the cran...

Page 71: ...hey can be fastened inside the crankcase half Remove the thrust washer 3 and the shim 2 Slide the 2 centring bushings out of the casing Remove the O ring from the output shaft Fasten the right crankcase half onto the installation stand Pull up the fork guiding rods 4 by nearly 1 5 cm and move them aside to gether with the gearbox forks 5 Remove the selector drum 6 with the relevant shim if any fro...

Page 72: ...Use the two threaded rods to fasten the special tool 1 to the crankcase half and pull the crankshaft out of the crankcase half WARNING If the procedure described above is not possible heat the crankcase half up to nearly 100 C Clean all parts check them for wear and replace if necessary WARNING In case of engine overhaul we recommend to replace all gaskets oil seals O rings and bearings UPON REMOV...

Page 73: ...G 1 CR 65 2012 ENGINE OVERHAUL Workshop Manual Ed 09 2011 Section G ...

Page 74: ...ck G 8 Piston ring gap measurement G 8 Piston and cylinder measurement piston assembly clearance determination G 8 Reed valve intake flange G 9 Gearbox control shaft disassembly G 10 Gearbox control check for component wear G 10 Gearbox control shaft pre assembly G 10 Clutch check for component wear G 11 Plate pack pre assembly G 11 Kick start pedal shaft pre assembly G 12 Gearbox shafts check for...

Page 75: ... bushings and place the crank case halves on a flat surface big enough to avoid damaging the sealing surfaces of the crankcase halves To this end we recommend using a wood plane Bearings and sealing rings should never be fitted without a suitable press otherwise pay utmost attention and use other suitable tools When the casings reach 150 C cold bearings fall in the relevant seats without any effor...

Page 76: ...uitable punch to push the ball bearing from the outside Push the new ball bearing from the inside fully home Input shaft needle roller bearing 3 Use a suitable Ø 12 16 mm puller to remove the needle roller bearing from the casing Push the new needle roller bearing fully home Selector drum ball bearing 4 Use a suitable puller to remove the roller bearing from the casing Push the new ball bearing fu...

Page 77: ...om the outside Push the new ball bearing from the inside fully home Smear Loctite 243 on the screw 3 thread and fit it LIGHTLY PUSH THE NEW NEEDLE ROLLER BEARINGAGAINST THE CASING TO AVOID DAMAGING THE LATTER Selector drum ball bearing 5 Use a suitable punch to push the ball bearing from the outside Push the new ball bearing from the inside fully home Output shaft needle roller bearing 6 Use a sui...

Page 78: ...ways check the drive shaft axes misalignment when reusing the crankshaft Max drive shaft axes misalignment 0 05 mm Check the radial clearance to the connecting rod big end bearing Max radial clearance 0 03 mm Actions on clutch cover Kick start pedal shaft oil seal 1 Push the old oil seal from inside out Force the new oil seal in from outside with open side inwards ...

Page 79: ... oil seal Push the old oil seal from inside out From the outer side force the new oil seal in with the open side outwards Water pump ball bearings Slide both bearings out of the water pump shaft First key the ball bearing fully against the shaft Then key the ball bearing sealed on both sides Grease the water pump oil seal Force the water pump shaft completely inside the clutch cover Then make sure...

Page 80: ... the value exceeds the indicated one check the piston ring and cylinder wear If the piston and cylinder wear respect the tolerances replace the piston ring Piston and cylinder measurement and piston assembly clearance deter mination To determine the cylinder wear the cylinder is measured by means of a feeler gauge placed 10 mm and 50 mm under the sliding surface upper edge Measure the cylinder dia...

Page 81: ...llation clearance of 0 065 mm MARKING PISTON MEAS CYLINDER MEAS A 44 955 44 960 mm 45 025 45 030 mm B 44 961 44 965 mm 45 031 45 035 mm C 44 966 44 970 mm 45 036 45 040 mm D 44 971 44 975 mm 45 041 45 045 mm E 44 976 44 980 mm 45 046 45 050 mm Reed valve intake flange WARNING Over time the reeds loose tension with a consequent power loss Damaged or worn out reeds shall be replaced If the reed valv...

Page 82: ...heck wear on engagement points on the shaped selector plate Check the guiding pin fixed seat and wear Compression spring 5 Check the compression spring pre load for the sliding plate Gearbox forks 7 Check for wear of gearbox fork end parts and of the selector drum driving dowels Selector drum 8 Check for wear of the shaped grooves Check for wear of selector drum supporting points WARNING The selec...

Page 83: ...surface A of the lined plate If the pitting exceeds 0 50 mm replace the hub Clutch housing 6 Check the thrust surfaces B wear of the lined plates If the pitting exceeds 0 50 mm replace the clutch housing Supporting bushing 7 Insert the supporting bushing in the clutch housing and check the clearance Plate pack pre assembly Fasten the input shaft in the vice use protection jaws Insert the thrust wa...

Page 84: ...g A above the spring end part Remove the kick start pedal shaft from the vice Gearbox shafts component wear check Fasten the input and output shafts in the vice use protection jaws Remove the gears and check for wear and seizure signs in the following points the supporting points of the input and output shafts and of the neutral gears the gear front couplings the teeth sides of all gears the tooth...

Page 85: ...washer 7 Then check that all gears move freely Output shaft assembly Fasten the output shaft with the splined end down in the vice use protection jaws Properly oil all components before assembly Insert the 2nd neutral gear 1 with the teeth bevelling downwards and fit the circlip 2 with the sharp edge upwards Insert the 6th sliding gear 3 with the fork slot upwards and fit the circlip 4 with the sh...

Page 86: ......

Page 87: ...H 1 CR 65 2012 ENGINE REASSEMBLY Workshop Manual Ed 09 2011 Section H ...

Page 88: ... gearbox control shaft H 5 Clutch assembly H 5 Refitting the primary drive sprocket H 6 Refitting the starting coupling and kick start pedal shaft pre load H 6 Refitting the clutch cover H 7 Refitting the chain sprocket H 7 Refitting reed valve and intake flange H 8 Refitting the ignition system and adjusting the fixed spark advance H 9 Cylinder head installation H 10 Refitting the kick start peda...

Page 89: ... 2 in the input shaft sliding gear Use a screwdriver to slightly lift up the lower sliding gear of the output shaft and engage the gearbox fork 3 Engage the last gearbox fork 4 in the output shaft upper sliding gear USED GEARBOX FORKS MUST BE REFITTED IN THE SAME SLIDINGGEARTHEYWEREBEFORE FORTHISREASON UPON REASSEMBLYPAYATTENTIONTOTHESIGNSMARKEDDURING DISASSEMBLY MAKESURETHEBUSHINGSDONOTFALLFROMTH...

Page 90: ... screws in the ignition side casing must be the first to be tightened fol lowing a cross pattern Tightening torque 10 Nm Tighten the other screws to 10 Nm and make sure all shafts move freely Fasten the engine into the installation stand After tightening the casing screws check the axial clearance of the selector drum The selector drum axial clearance must be of 0 30 0 50 mm The axial clearance ca...

Page 91: ...ol shaft and carefully insert it in the engine casing Push the sliding plate back and insert the gearbox control shaft fully inside the engine casing Fit the gear shift pedal and insert in sequence all gears by contemporarily turning the input shaft Afterwards remove the gear shift pedal again Clutch reassembly Fit the idle gear 5 with the beat faced to the casing on the supporting pin Insert the ...

Page 92: ... tool for the primary drive sprocket and tighten the hexagon nut to 100 Nm Remove the retaining tool Refitting the starting coupling kick start pedal pre load Fit the starting coupling 1 as shown in the kick start pedal shaft picture Pre load the kick start pedal shaft counterclockwise and engage the starting coupling on the stopping plate a high pre load is not necessary Oil the sliding points fi...

Page 93: ...crankshaft and the water pump shaft UPON CLUTCH COVER REASSEMBLY MAKE SURE THE CRANK SHAFT PLANE POINT ENGAGES IN THE RELEVANT GROOVE OF THE WATER PUMP SHAFT IF NECESSARY SLIGHTLY TURN THE CRANKSHAFT Position the clutch cover Insert all screws in the clutch cover and tighten them to 10 Nm see diagram for screw length Check that the kick start pedal shaft moves freely Refitting the chain sprocket O...

Page 94: ...ntake flange Insert the reed valve with a new gasket in the engine casing fit the intake flange and fasten by means of 4 screws Fit the two remaining flanged screws on the cylinder base and tighten the 4 flanged screws to 18 20 Nm Screw the exhaust fitting and the gasket to the cylinder ...

Page 95: ...the wrench 2 in the two holes and tighten the flanged nut to 60 Nm Move the piston to the L D C and place the adjusting gauge on the cylinder upper edge Now the internal rotor must be turned counterclockwise until the piston upper edge touches the adjusting gauge see sketch Now turn the stator so that the two markings 3 match BEFORE ADJUSTING THE FIXED SPARK ADVANCE IT IS NECES SARY TO CORRECTLY A...

Page 96: ...ide Fit the cylinder head screws with the new copper sealing rings and tighten them in two steps first start them without tightening then tighten definitively to the preset torque of 18 Nm Screw the spark plug Fit the water hose 3 and fasten it with the two clamps Refitting the kick start pedal Screw the kick start pedal 4 as shown for the kick start pedal shaft Refitting the ignition cover Refit ...

Page 97: ...oil filling procedure Screw the gearbox breather pipe to the engine casing Screw the gearbox oil bleeding screw 1 with its new sealing ring and tighten to 12 Nm Remove the oil filling screw from the clutch cover and fill in 0 50 l of gearbox oil Refit the oil filling screw ...

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Page 99: ...I 1 CR 65 2012 I FRONT SUSPENSION Workshop Manual Ed 09 2011 Section ...

Page 100: ...I 2 CR 65 2012 FRONT SUSPENSION Workshop Manual Ed 09 2011 Front suspension I 3 Removing front fork I 4 Fork spring features I 5 Fork oil I 5 Cleaning the fork legs dust seals I 6 ...

Page 101: ... 65 FRONT SUSPENSION Workshop Manual Ed 09 2011 Front suspension Upside down hydraulic fork with advanced axle compression and rebound damping adjustment with ø 35 mm legs The wheel travel on the forks axle is of 220 mm ...

Page 102: ...l value on assembly Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows Release the front brake hose and the engine stop cable from the hose ring 1 inside the Number holder Release the front brake hose from the U bolt 2 that fastens the hose to the left fork leg protection 1 2 ...

Page 103: ...s to steering head and bottom yoke Remove the fork legs After all necessary operations refit the fork legs and the front wheel as described in section Y Set height A back to original value Fork spring features Length 380 mm Constant K 3 5 Nm Fork oil Level 100 2 mm without spring preload tube and with tube fully home Oil quantity in each fork leg 210 cu cm 2 3 3 Oil level 100 2 mm TIGHTENING TORQU...

Page 104: ... of the built up dirt on the legs from entering inside the fork and thus damaging the oil seals with consequent sealing loss Any oil leakage from the fork legs can represent a danger when using the vehicle since the presence of oil on the brake disc or on the pads reduces the braking effect In case of contacts between friction parts and oil thoroughly clean with detergent suitable for brakes Clean...

Page 105: ...J 1 CR 65 2012 J REAR SUSPENSION Workshop Manual Ed 09 2011 Section ...

Page 106: ...J 3 Removing the rear shock absorber J 4 Removing the chain rear casing J 4 Disassembling and servicing the swinging arm J 5 Servicing the swinging arm pivot J 7 Servicing the rear rocker arm and suspension drop drag link J 7 Chain roller chain guide chain slider J 8 Adjusting the shock absorber J 8 ...

Page 107: ...t lb Loctite 243 Rear suspension The suspension of this motorcycle consists of a shock absorber a series of linkages and a swinging arm The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions The hydraulic damping can be adjusted both in rebound and in compression Periodically check all components for wear LUBRICATION POINTS GREASE ...

Page 108: ...on the chassis Remove the shock absorber lower retaining screw 3 and the upper one 4 and then slide the shock absorber 5 out Upon reassembly insert the upper pin 4 from the right to the left and the lower one 3 from the left to the right Removing the chain rear casing Remove the rear chain protection casing 1 by cutting the two ties 2 that fasten it to the swinging arm ...

Page 109: ...round Remove the secondary drive chain 1 and detach the rear brake line 2 from the guide A on the swinging arm Remove the wheel axle nut 3 and the wheel axle B There is no need to loosen the chain tensioners 4 on the swinging arm in this way the chain tension will remain unchanged after reassembly Slide the wheel C out Remove the pin 5 that connects the shock absorber linkage to the swinging arm A...

Page 110: ... 4 using a 17 mm socket wrench on the left and a 14 mm one on the right to remove the nut 2 of the swinging arm pivot 3 and the swinging arm A itself Check the swinging arm pivot 3 parallelism Check for wear of the needle roller bearings D and the relevant pins E turn the pins inside the roller bearings if you feel any tightness or hear noise replace them TIGHTENING TORQUE FIGURES 2 3 70 Nm 7 1 Kg...

Page 111: ... link 2 still in place connected to swinging arm and chassis respectively rock them both back and forth in all directions to check for radial and axial clearance Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation If any radial clearance is detected remove the part from swinging arm or chassis and check inner spacer A bushi...

Page 112: ...the rider weight The shock absorber adjustment affects both the stability and the handling of the motorcycle We recommend to act carefully after having changed the standard setting Before performing any change we rec ommend to measure a reference value A with bike on the central stand and rear wheel lifted from the ground Have the bike resting on ground without rider Measure dimension A The differ...

Page 113: ...L 1 CR 65 2012 L BRAKES Workshop Manual Ed 09 2011 Section ...

Page 114: ...al Ed 09 2011 Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Pads removal L 5 Pads installation L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 ...

Page 115: ...ipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake disc 10 Rear brake master cylinder 11 Rear brake control pedal ...

Page 116: ...ameter 260 mm Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter mm 140 Rear brake disc thickness when new mm 3 10 Wear limit 2 5 mm Disc warpage must not exceed 0 15 mm check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the four retaining screws Onassembly cleanallmatingsurfacesthoroughlyandtightenthescrews t...

Page 117: ...rily Pads removal Remove the retaining ring 1 on the front calliper or the split pin 5 on the rear calliper Loosen the pin 2 Remove the pads 4 Do not work the brake lever or pedal while removing the pads Pads installation Fit the new brake pads 4 having care to position the clip 3 correctly Screw the pin 2 and refit the retaining ring 1 on the front calliper or the split pin 5 on the rear one The ...

Page 118: ...fluid only air at first then slightly close the valve Release the lever and wait a few seconds Repeat the process until you see only fluid coming out of the hose Tighten the bleed valve to the indicated torque restore the fluid level A and refit the rubber gaiter 4 and cover 2 of the tank Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake ...

Page 119: ...drain the fluid only air at first then slightly close the valve Release the pedal and wait a few seconds Repeat the process until you see only fluid coming out of the hose Tighten the bleed valve to the specified torque and check fluid level B in the reservoir before refitting the cap A If the bleeding procedure was performed correctly the pedal will no longer have that mushy feel If not so repeat...

Page 120: ... of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damage to painted parts Do not mix two brands of fluid This would reduce boil over point leading to loss of braking efficiency or degrading of rubber parts Replacement procedure is as fol...

Page 121: ...leed valve and fill the reservoir with fresh fluid Loosen the bleed valve operate lever or pedal tighten the valve keeping lever or pedal pressed and then release them Repeat the process until the circuit is full and you can see clear fluid coming out of the plastic hose now tighten the bleed valve Top up with fluid up to level A or B and refit rubber gaiter and reservoir cover After changing the ...

Page 122: ......

Page 123: ...M 1 CR 65 2012 M ELECTRICAL SYSTEM Workshop Manual Ed 09 2011 Section ...

Page 124: ...1 Wiring diagram M 3 Electrical components location M 4 Spark plug M 5 Handlebar switches M 6 Left hand switch M 6 Ignition system resistance values stator M 6 Ignition coil M 6 Ignition static parameters measurement with peak voltage adapter M 7 Important M 8 ...

Page 125: ...range black black blue white red black green white red green Pulsante di arresto Generatore pick up ELECTRICAL SYSTEM Workshop Manual Ed 09 2011 Wiring diagram Cable colour bk black bl blue gn green or orange re red ye yellow wh white Stop button Ignition coil Generator ...

Page 126: ...ical component location The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the tank on the chassis right side Electronic control unit 3 on steering tube rake behind the Number holder ...

Page 127: ...moving the spark plug It is good practice to closely inspect the spark plug after removal as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating carburetion ignition and the general condition of the engine Before refitting the spark plug accurately clean the insulator with a wire brush Smear some graphite grease on spark plug thread do it fully h...

Page 128: ... reading on multimeter 55 Ω 10 Ω Condenser charge coil across black red cable and green white cable reading on multimeter 900 Ω 180 Ω WARNING it is not necessary to remove the stator to take the measurement Ignition coil Loosen the spark plug cap and disconnect the cable that controls the pri mary side Measure the resistance of the ignition coil primary side across the plug con trolling the primar...

Page 129: ...ltage green red and black cables the red prod of the peak voltage adapter on the green red cable the black prod on the black cable then separate the connector 1 reading on multimeter 40 volt 5 volt Same measurement but with CDI unit connected reading on multimeter 35 volt 5 volt Check the condenser charge coil on output voltage black red and green white cables the red prod of the peak voltage adap...

Page 130: ...y to duly protect the following parts from water a Rear opening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings e Rear suspension drag drop link It is necessary to PREVENT WATER OR HIGH PRESSURE AIR JETS from reaching the ELECTRIC PARTS ...

Page 131: ...N 1 CR 65 2012 N ENGINE COOLING Workshop Manual Ed 09 2011 Section ...

Page 132: ...N 2 CR 65 2012 ENGINE COOLING Workshop Manual Ed 09 2011 Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 133: ...cylinder head and radiator The cylinder and piston assembly will overheat and seize and in the worst scenario crankshaft damage may result If the event of engine overheating check that the radiator is full Level in the radiator must be checked from cold see Section D In the event you need to check level when the engine is hot be sure to discharge pressure gradually Loosen the plug 1 of the radiato...

Page 134: ...ng system uses a centrifugal pump located to the right of the cylinder head and two downdraft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Radiator to head pipe 5 Water pump 6 Breather hose 7 Radiator connecting pipes 8 Water pump radiator lower pipe 9 Head water pump pipe 10 Coolant bleeding screw ...

Page 135: ...o radiator Straighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or hardening d...

Page 136: ......

Page 137: ...P 1 CR 65 2012 Workshop Manual Ed 09 2011 HYDRAULICALLY CONTROLLED CLUTCH Section P ...

Page 138: ...5 2012 Workshop Manual Ed 09 2011 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system P 3 Draining clutch fluid P 4 Servicing the clutch master cylinder P 4 Filling draining the clutch hydraulic system P 5 ...

Page 139: ...is transmitted from the crankshaft to the gearbox input shaft via the gear on the clutch housing 8 The clutch housing accommodates friction plates 9 and steel plates 10 that operate the clutch hub 6 secured to the gearbox input shaft 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Pressure plate 5 Actuator piston 6 Clutch hub 7 Bleed fitting 8 Clutch housing with clutch ...

Page 140: ...eservoir cap and bellow diaphragm and operate the control lever until draining all fluid Clutch master cylinder servicing Drain the circuit detach the master cylinder from the left side of the handlebar and take it apart Replace all seals reassemble the master cylinder and refit it to the handlebar Reconnect the hose and fill fresh fluid into the reservoir Bleed the system as described at page P 4...

Page 141: ...alve 5 Connect the bleed valve to a pipe and use a syringe 6 to fill in the fluid of the type specified in the LUBRICANT TABLE at page A 9 until topping up the master cylinder reservoir NEVER use brake fluid Check that fluid level is never lower than 3 mm below the upper edge A of master cylinder body Refit any parts you have removed Make sure the clutch lever reacts properly when activated otherw...

Page 142: ......

Page 143: ...S 1 CR 65 2012 Workshop Manual Ed 09 2011 FUEL SUPPLY Section S ...

Page 144: ...rtial load C S 4 Full load D S 4 Carburettor drawing S 5 Removing and refitting the carburettor S 6 Disassembling the carburettor S 8 Checking the cold start device S 9 Checking taper needle and throttle valve S 10 Checking the floater needle valve S 10 Checking carburettor jets and gaskets S 10 Reassembling the carburettor S 10 Emptying the carburettor bowl S 11 Checking the floater level S 11 ...

Page 145: ...NGINEAND IN EXTREME CASES IRREPARABLE DAMAGES TOO MUCH OIL CAUSES EXCESSIVE SMOKE AND SOILS THE SPARK PLUG AND THE EXHAUST VALVE TO GET A LEAN MIXTURE CAREFULLY REDUCE THE JETS STEP BY STEP BY ONE NUMBER RESPECTIVELY TO AVOID PISTON OVERHEATING AND SEIZURE WARNING If despite the setting change the engine does not work properly check for mechanical faults or problems in the ignition system Main inf...

Page 146: ...its maximum power suddenly at high rpm that means the car buretion is too rich i e the fuel level is too high or the main nozzle does not feature a proper sealing Partial load C Operation with throttle valve partially opened Rpm are controlled by the taper needle only shape and position The operation at partial load at low rpm is determined by the idle adjustment and the maximum jet peaks If the e...

Page 147: ...or drawing 1 Air adjusting screw 2 Throttle valve spring 3 Air adjuster spring 4 Throttle valve 5 Needle valve 6 Taper needle 7 Maximum jet seat 8 Maximum jet 9 Minimum jet 11 Cold kick start lever 13 Floater bowl 14 Floater pin 15 PVC hose 16 Idle adjustment screw ...

Page 148: ...acting on the carburettor thoroughly clean the motorcycle Close the fuel cock 1 and remove the pipe 2 from the carburettor Remove the clamp 3 and release the carburettor breather pipes from the transmission oil breather pipe Loosen the two screws 4 Remove the cover 5 of the carburettor together with the throttle valve ...

Page 149: ...in Section E Disconnect the silencer from the rear chassis supporting plate Remove the two lower screws 7 and loosen the two upper screws 8 that connect the rear chassis to the front chassis Turn the rear chassis 9 to completely release the carburettor from the union 10 that connects the air filter Loosen the tie 11 and remove the carburettor from the intake fitting ...

Page 150: ...be sufficiently big to arrange in an orderly way all carburettor single components Disconnect all carburettor breather pipes Loosen the four screws 1 and remove the float chamber 2 with the relevant gasket Remove the floater 3 axle Remove the floater with the needle from the needle valve Remove the maximum jet 4 Remove the screw 5 of the floater needle valve body retaining plate 7 Remove the minim...

Page 151: ...home counting and recording the turns Remove the air adjuster screw the spring the washer and the O ring Checking the cold start device To remove the starting piston 2 it is necessary to straighten the bent washer to be able to loosen the retaining nut 3 The cold start device must be easy to activate The piston 4 must not feature evident scratching or deposits ...

Page 152: ...ng the floater needle valve Check for no dents on the needle valve sealing surface There must be no dirt between the valve seat and the floater needle Checking the carburettor jets and gaskets Thoroughly clean all carburettor components and blow them with compressed air Replace all gaskets and O rings Reassembling the carburettor For reassembly follow the removal procedure in the reverse order Con...

Page 153: ...g into the bowl and clean the closure screw with compressed air Afterwards refit the closure screw with its seal and tighten it to 4 Nm then open the fuel cock and check for no leakages in the bowl Checking the floater level Place the carburettor with the floater high horizontally The spring in the floater needle valve must not be compressed In this position the distance between the floater edge a...

Page 154: ......

Page 155: ...W 1 CR 65 2012 W SPECIAL TOOLS Workshop Manual Ed 09 2011 Section ...

Page 156: ... Crankshaft removing tool 2 Commercial Bearing puller 3 Commercial Insert for bearing puller 12 16 mm 4 8000 H7678 Primary gear retainer 5 Commercial Flywheel and clutch retainer 6 8000 H7679 Spark advance adjusting gauge 7 8000 46613 Flywheel puller 8 Commercial Puller 9 Commercial Pliers for cooling system clamps 1 2 3 4 5 6 7 8 9 ...

Page 157: ...lf loose causing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accordance with thread diameter pitch and specific application These figures are obtained after clea...

Page 158: ...RIPTION MEASURE Qty NOMINAL TORQUE Nm NOTES U bolt to steering head retaining screw M10 2 35 U bolt closing screw M8 4 28 Fork plate retaining TORX screw M8 7 25 Fork guard to fork bottom retaining screw M6 6 6 Steering upper nut 10 1 Nm 0 73756 ft lb CHASSIS DESCRIPTION MEASURE Qty NOMINAL TORQUE Nm NOTES Check nut for lug adjustment M6 1 10 Lever joint retaining screw M6 1 10 LOCTITE 243 Brake l...

Page 159: ...g retaining self threading screw 2 4 REAR SUSPENSION DESCRIPTION MEASURE Qty NOMINAL TORQUE Nm NOTES Front mudguard retaining screw with collar M6 4 6 Number holder retaining screw with collar M6 1 6 Front mudguard part connection screw 4 1 5 Rear mudg front retaining screw with collar M5 2 6 Number holder to rear mudg retaining screw 2 1 5 Side panel rear retaining screw with collar M5 2 6 Side p...

Page 160: ... Rear brake calliper retaining screw M8 2 25 LOCTITE 243 Rear brake master cylinder retaining screw M6 2 10 LOCTITE 243 Rear brake master cylinder retaining nut M6 2 10 LOCTITE 243 1 Nm 0 73756 ft lb DESCRIPTION MEASURE Qty NOMINAL TORQUE Nm NOTES Tank front retaining screw M6 1 6 Cock retaining self threading screw 2 1 5 SUPPLY SYSTEM WHEELS AND BRAKES DESCRIPTION MEASURE Qty NOMINAL TORQUE Nm NO...

Page 161: ...0 Nm 5 10 Kgm 36 9 ft lb Flywheel flanged nut M10x1 25 M12x1 60 Nm 6 12 Kgm 44 3 ft lb Cylinder head screws M7 18 Nm 1 84 Kgm 13 3 ft lb Cylinder base flanged nuts M8 18 Nm 1 84 Kgm 13 3 ft lb Clutch screws M6 14 Nm 1 43 Kgm 10 3 ft lb Oil bleeding screw M10 12 Nm 1 22 Kgm 8 9 ft lb Clutch cover screws M6 10 Nm 1 02 Kgm 7 4 ft lb Clutch hub screws M10 48 50 Nm 4 89 5 10 Kgm 35 4 36 88 ft lb Kick s...

Page 162: ...al spacers M4 2 Nm 0 2 Kgm 1 45 ft lb Steel screws on brass copper aluminium M4 2 Nm 0 2 Kgm 1 45 ft lb Steel screws on iron steel M4 3 Nm 0 3 Kgm 2 2 ft lb Steel screws on plastic with metal spacers M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb Steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb Steel screws on plastic with metal spacers M6 6 5 Nm 0 65 Kg...

Page 163: ...Y 1 CR 65 2012 Y CHASSIS AND WHEELS Workshop Manual Ed 09 2011 Section ...

Page 164: ...Front wheel Y 4 Front wheel removal Y 5 Front wheel installation Y 6 Rear wheel Y 7 Rear wheel removal Y 8 Wheel servicing Y 9 Wheel axle warpage Y 9 Axle runout over 100 mm Y 9 Wheel spokes Y 10 Wheel rim warpage Y 10 Rear chain sprocket secondary drive sprocket and chain Y 11 Check for sprocket wear Y 12 ...

Page 165: ...hassis The single frame branches off at the exhaust and is made of steel tubes with circular rectangular and ellipsoidal section the rear chassis is made from light alloy A badly damaged chassis must be replaced Lubrication points lubricant 1 Steering bearings grease ...

Page 166: ...shop Manual Ed 09 2011 Front wheel Light alloy wheel hub and rim with high strength steel spokes Make type and size of light alloy wheel rims 1 6x14 Make type and size of tyre Pirelli Scorpion MX 60 100 14 29M NHS Cold tyre pressure 0 8 Bar ...

Page 167: ...ced on the left side Loosen the two screws 2 that fasten the pin head to the fork bottom on the right side Slide the pin 3 out from the right side and remove the wheel having care to recover the two spacers one for each side Do not operate the front brake lever when the wheel has been removed this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top ...

Page 168: ...the wheel should be turned Tighten the two screws 2 that retain the pin head to the fork Tighten the screw 1 on the fork L H Remove the stand located under the vehicle Act repeatedly on the front brake lever until bringing the pads against the disc Loosen the screws 2 of the fork bottom With front wheel braked act several times on the fork to complete the leg align ment Tighten the screws 2 to the...

Page 169: ...Workshop Manual Ed 09 2011 Light alloy wheel hub and rim with high strength steel spokes Make type and size of light alloy wheel rim 1 6x12 Make type and size of tyre Pirelli Scorpion MX 12 50M NHS Cold tyre pressure 0 8 Bar Rear wheel ...

Page 170: ...hain tensioners 2 in this way the chain tension will remain un changed after reassembly Extract the complete rear wheel keeping the spacers located at the hub sides Do not operate the rear brake pedal when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top For reassembly follow the removal procedure in the reverse o...

Page 171: ... Discard the bearings after removal Never reuse them Before installing the new bearings check to ensure the seat is clean and shows no grooves or scratches Lubricate the seat before installing the bearing Drive the bearing into place using the special installer that only applies pressure to the outer race Fit the spacer and the other bearing Check for perfect alignment as you slide the axle into p...

Page 172: ...ool such as a screwdriver a clear crisp sound indicates proper tightening a dull sound means that the spokes need to be tightened Wheel rim warpage The table below reports the allowed limits for wheel rim warpage Exceeding runout or out of round are generally due to worn bearings When this is the case replace the bearings If this does not solve the problem change the wheel rim or the wheel Standar...

Page 173: ...the side shows the profiles of a normally worn and an exceedingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the five screws that retain it to the hub Chain and sprockets must always be replaced as a set Tightening torque figures 3 15 Nm 1 5 Kgm 11 6 ft lb LOCTITE 243 ...

Page 174: ...rocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension If you expect to ride on muddy or wet terrain slacken the chain a bit Riding on muddy terrain significantly increases chain and sprocket wear ...

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