Husqvarna SM 50 / 2011 Workshop Manual Download

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L.3

H02147

H02148

H02149

H02150

BRAKES

Ed. 01-09-2010

Braking system

The braking system uses two independent circuits. Each system is equipped 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

Summary of Contents for SM 50 / 2011

Page 1: ...Workshop Manual CR 50 2011 SM 50 2011 Ed 01 09 2010 ...

Page 2: ... any errors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 10 2009 ...

Page 3: ...om 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 CR 50 ZKHCR5030BV000001 SM 50 ZKHSM5030BV000001 1 Chassis serial number CR 50 2011 SM 50 2011 ...

Page 4: ...lem 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 to the part that ne...

Page 5: ...ral Information A Maintenance B Troubleshooting C Settings and Adjustments D General Procedures E Engine F Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications apply to all models ...

Page 6: ......

Page 7: ...b 1 b Ed 01 09 2010 IMPORTANT NOTICES Section ...

Page 8: ...ections carried out at authorised HUSQVARNA dealers The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client The warranty becomes NULL AND VOID if the motorcycle is rented Notes Left and right side is determined when seated on motorcycle Z number of teeth A Austria AUS Australia B Belgium BR Brazil CDN Canada CH Switzerland D Ge...

Page 9: ...A 1 A Ed 01 09 2010 GENERAL INFORMATION Section ...

Page 10: ... A 3 Fuel system A 3 Lubrication A 3 Cooling A 3 Ignition system A 3 Starter A 3 Drive and Transmission A 3 Chassis A 3 Suspension A 3 Brakes A 3 Wheels A 4 Tyres A 4 Electrical components location A 4 Overall dimensions Weight A 5 Capacities A 5 ...

Page 11: ...g type NGK BR8 ECM Spark plug electrode gap 0 7 mm Kick start Drive and transmission Drive pinion gear Z 10 Sprocket Z 43 Transmission ratio 4 3 Chassis Single frame in steel tubes with rectangular and circular section rear chassis in steel squared sectioned tubes Suspension Front Type hydraulic fork with advanced stanchion tubes ø 32 mm Travel 185 mm Rear Type progressive with hydraulic single sh...

Page 12: ... 1 6x10 SM Front in light alloy 1 5x10 Rear in light alloy 1 5x10 Tyres CR Front PIRELLI SCORPION 60 100 12 36M Rear PIRELLI SCORPION 2 75 10 37J NHS SM SAVATECH 3 50 10 51P TL MC31 S RACER Cold tyre pressure Front 1 2 Kg cm2 Rear 1 5 Kg cm2 Electrical components location The ignition system includes the following elements Generator on the inner side of L H crankcase half cover Electronic transduc...

Page 13: ... CASTROL MOTORCYCLE COOLANT 0 55 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 Drive chain lubrication CASTROL CHAIN LUBE RACING Grease lubrication CASTROL LM GREASE 2 Electric contact protection CASTROL METAL PARTS CLEANER Fillers for radiator AREXONS LIQUID FILLER Air filter oil AGIP FORMULA FILTER Foam air filter protection oil Air filter de...

Page 14: ......

Page 15: ...B 1 B Ed 01 09 2010 MAINTENANCE Section ...

Page 16: ... on intake manifold Idle speed adjustment hot engine Washers of washer valve check Clutch shoes wear Clutch drum wear check Water pump shaft and relevant bearing wear check Water pump impeller wear check Cylinder and piston wear check Axle shafts offset check Connecting rod big end bearing radial clearance check Connecting rod big end bearing radial clearance Connecting rod small end bearing radia...

Page 17: ...on check Front lever and brake pedal operation check and adjustment Braking system screw tightening check Exhaust system check Control cable lubrication and smoothness check Air filter and air box cleaning Shock absorber and fork operation check Swinging arm mount check Steering bearing check and or adjustment Screw tightening check Spoke tension and rim concentricity check Tyre pressure and condi...

Page 18: ... level check Coolant level check Brake fluid level check Brake seal wear check Brake operation check Control cable lubrication and adjustment Fork dust seal removal and cleaning Chain cleaning tensioning check and lubrication Air filter and air box cleaning Tyre pressure and wear check Fuel pipe condition check ...

Page 19: ...C 1 C Ed 01 09 2010 TROUBLESHOOTING Section ...

Page 20: ...lean 2 Fuel cock clogged Clean 3 Fuel feed pipe clogged Clean 4 Filter on carburettor fitting dirty Clean 5 Floater valve or floaters faulty Replace 6 Linkage is blocking floater valve Release Carburettor flooding 1 High fuel level in bowl Adjust 2 Floater valve or floaters worn or stuck open Replace or release Engine stalls 1 Fouled spark plug Clean easily 2 Carburettor jets clogged Clean 3 Low i...

Page 21: ...lle washer load Replace Engine has low power 1 Dirty air filter Clean 2 Carburettor main jet clogged or wrong size Clean or replace 3 Poor fuel quality Replace 4 Intake coupling loose Tighten 5 Spark plug electrode gap too wide Adjust 6 Insufficient compression Identify cause Engine overheats 1 Combustion chamber and or piston crown fouled with carbon deposits Clean 2 Insufficient oil inside crank...

Page 22: ...st Damping is 1 Insufficient oil 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 R...

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

Page 24: ......

Page 25: ...D 1 D SETTINGS AND ADJUSTMENTS Ed 01 09 2010 Section ...

Page 26: ...12 Rear brake fluid level check D 12 Oil level check D 13 Oil replacement D 13 Coolant level check D 14 Coolant replacement D 14 Air filter check and cleaning D 15 Chain adjustment D 16 Chain lubrication D 17 Removal and cleaning D 17 Chain washing D 17 Chain lubrication D 17 Rear shock absorber adjustment D 18 Shock absorber spring preload adjustment D 19 Shock absorber compression and rebound da...

Page 27: ...D 3 H02123 SETTINGS AND ADJUSTMENTS Ed 01 09 2010 H06248 CR 50 SM 50 ...

Page 28: ...g screw Tank 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 screws 4 and the side panels Disconnect the breather hose 5 Remove the retaining screw 6 and then the tank 7 together with scoops ...

Page 29: ...ubber cap 1 at cable end push and pull cable 2 to make sure it has about 2 mm free play if not so loosen the lock ring nut 3 and suitably turn the adjuster screw 4 loosen to decrease play or tighten to increase it tighten back the lock ring nut 3 Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide Never run the engine indo...

Page 30: ...er screw 2 clockwise to fully closed position and then turn it back 3 turns Gradually loosen the screw 1 until achieving 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 clock...

Page 31: ...Ed 01 09 2010 Using long nose pliers lock clutch rotation and undo nut 2 with a 15 mm wrench Remove washer 3 Fit puller 4 by screwing screws 5 inside clutch threaded holes Screw puller central screw 6 until removing clutch assembly then remove puller from clutch assembly ...

Page 32: ...nterweights 8 To change clutch setting just vary the position of Belleville washers It can be Harder or Softer Clutch setting shall be changed on all the three Belleville washer units STANDARD SETTING 14 washers pack size 16 51 mm SOFT SETTING 14 washers pack size 16 3 mm HARD SETTING 15 washers pack size 16 64 mm Reassemble all parts in the reverse order compared to disassembly securing screws 7 ...

Page 33: ...stem hence an extension of the lever stroke If the brake lever feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE 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...

Page 34: ...Position adjustment Brake lever 1 can be adjusted by loosening screws 2 When finished tighten screws again 2 Lever distance adjustment Lever 1 distance from throttle twistgrip can be adjusted using ring nut 3 turn it clockwise A to approach the lever and turn it counter clockwise B to drive it away ...

Page 35: ... adjusted according to individual needs For adjusting proceed as follows Loosen the screw 1 turn the cam 2 in order to raise or lower the brake pedal 3 within the range available A When finished tighten the screw 1 Once this adjustment is completed adjust the free play of the pedal following the instructions provided in paragraph Rear brake pedal free play adjustment ...

Page 36: ...ight glass 1 must be above the minimum notch on master cylinder reservoir To restore fluid level loosen the two screws 2 and remove cover 3 Top up using a fluid specified in LUBRICATION AND SUPPLIES table A decrease of the fluid level will let air into the system hence an extension 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...

Page 37: ... top up using a syringe inside level screw hole Oil replacement Be careful not to touch hot engine oil Drain the oil with WARM ENGINE proceed as follows Remove oil filler cap 1 put a drip pan under engine remove oil drainage plug 2 evacuate the exhausted oil refit oil drainage plug 2 15 Nm 1 5Kgm 11 06 ft lb pour the recommended quantity of oil through the filler hole 1 Check oil level as specifie...

Page 38: ...he cooling system Avoid removing radiator cap when engine is hot as coolant may spout out and cause scalding Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water Coolant replacement Place a vessel on the L H side of the cylinder under the screw 1 Undo screw A and slightly lift tank B SLOWLY open the R H radiator cap 2 slope the motorcycle on the le...

Page 39: ...sable Check the correct tightening of the clamps B Air filter check and cleaning Remove the saddle as described in the relevant paragraph Remove plastic frame 1 by releasing the corresponding clip 2 and then remove air filter 3 Clean filter 3 with suitable products dip it in the special oil squeeze it until all the oil has come out and then let it dry before reassembly We recommend having always a...

Page 40: ...in tension so as to allow shim slide without any forcing and without the chain being too slack If it is not proceed as follows Loosen hexagon nut 1 Loosen check nuts 2 on both sides Turn screw 3 on both sides of rear swinging arm to increase or decrease chain tension taking special care to centre wheel inside rear swinging arm using the notches on swinging arm as a reference Once the desired tensi...

Page 41: ... guards as indicated in the corresponding paragra ph remove clip 1 master link 2 then remove chain 3 To reassemble reverse the above procedure Make sure that the chain is neither worn out nor damaged If the rollers or the links are damaged replace the chain by following the instructions given in the Scheduled Maintenance Chart Ensure that the sprockets are not damaged Wash and clean the chain as d...

Page 42: ...motorcycle in normal riding position with full riding gear on 3 Have someone else measure distance A again 4 The difference between these two measurements is the distance the rear end settles when the rider sits on the motorcycle RIDER SAG Recommended lowering is 20 mm 0 79 in with cold shock absorber 5 To achieve correct rider sag for your weight adjust the spring preload of the shock absorber se...

Page 43: ... nut 2 of the spring 3 3 Either with a hook wrench or an aluminium punch loosen the lock ring nut 4 Turn the adjuster ring nut as required 5 Adjust preload to suit your weight or riding style and tighten lock ring nut firmly tightening torque 20 Nm 2 Kgm 14 75 ft lb 6 Refit right hand side panel Be careful not to touch hot exhaust pipe while adjusting the shock absor ber The standard length of the...

Page 44: ...ndard setting 1 25 turns 0 25 from the fully closed posi tion To reset the standard setting turn lower adjuster 1 clockwise until reaching the fully closed position Then turn it back by the mentioned turns In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action Shock absorber springs 2 STANDARD K 5 daN mm ...

Page 45: ... the engine and see that the front wheel is lifted from the ground Press lightly on the handlebar grips to cause the front end to rotate the handlebar should turn smoothly 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 Remove bumper 1 Use a 6 mm Allen wrench to...

Page 46: ...verse order making sure to refit clamps 3 in the same direction and tightening screws 2 to 25 Nm 2 5 kgm 18 44 ft lb so that the front and rear distance between upper and lower clamp is alike After having refit handlebar make sure that throttle cable and front brake pipe are in the correct position Handlebar position change Handlebar position can be changed to better suit your riding style To perf...

Page 47: ...ection Check the hose 1 for leaks and replace it as required Remove the supply hose 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 ...

Page 48: ......

Page 49: ...E 1 E Ed 01 02 2010 GENERAL PROCEDURES Section ...

Page 50: ...guard removal E 4 Saddle removal E 5 Side panel removal E 5 Rear chassis complete with mudguard and air boxremoval E 6 Exhaust system removal E 8 Scoops and spoiler removal E 11 Transducer removal E 13 Engine removal E 14 Rear mudguard with filter box removal E 16 Radiator removal E 17 ...

Page 51: ...his 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: ...ERAL PROCEDURES Number holder removal Loosen front brake cable guide screw 1 Loosen screw 2 using a 8 mm ring wrench and lift number holder to remove it Front mudguard removal Loosen the four screws 1 with a 8 mm ring wrench and remove mudguard 2 H06256 2 ...

Page 53: ...ERAL PROCEDURES Saddle removal Turn the rear fixing 1 counterclockwise Remove saddle 2 from front retaining screw Side panel removal Remove the saddle as described in the relevant paragraph Loosen the retaining screws 1 and remove the side panels 2 and 3 ...

Page 54: ...described in section D Remove the exhaust silencer as described in the relevant paragraph Slacken the clamp 1 that secures the rubber coupling 2 of the air box at the carburettor end 3 Work with a 6 mm Allen wrench on the left side and a 12 mm ring wrench on the right side Remove nut 4 leaving pin in its position Remove the lower fixing 5 on both sides of the rear chassis using a 10 mm ring wrench...

Page 55: ...ES Remove pin 7 and subframe 6 with filter box Refit all the disassembled parts in reverse order making sure to correctly refit rubber union 2 onto carburettor so as to prevent it from sucking not filtered air See section X for tightening torque figures ...

Page 56: ... GENERAL PROCEDURES Exhaust system removal Remove the saddle as described in the relevant paragraph Remove the right hand side panel as described in the relevant paragraph Loosen the two screws 1 using an 8 mm wrench Remove silencer 2 with flexible mount 3 ...

Page 57: ...58 5 H02096 7 Ed 01 02 2010 GENERAL PROCEDURES Disconnect springs 4 from muffler 5 Loosen the screw 6 with a 8 mm ring wrench Remove muffler 5 Check seal 7 change if damaged To make reassembly operations easier smear some grease onto seal 7 ...

Page 58: ...URES Reassemble all parts in the reverse order compared to disassembly After hooking springs 4 screw muffler 5 and silencer 2 screws but do not tighten them Check exhaust system and sleeve 8 exact positions and then tighten screws See section X for tightening torque figures ...

Page 59: ...E 11 H06259 2 3 1 3 1 Ed 01 02 2010 GENERAL PROCEDURES Scoops and spoiler removal ...

Page 60: ...ve the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Loosen the screws 1 using a 8 mm ring wrench and with a Phillips screw driver loosen screw 2 and remove scoop 3 Repeat the procedure to remove the other scoop ...

Page 61: ...move saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Cut clamp 2 Loosen ground screw 3 using a 5 mm Allen wrench Disconnect the connector 4 Using a 8 mm ring wrench loosen the two screws 5 of transducer mounting bracket then remove transducer 6 with bracket ...

Page 62: ...ibed in the relevant paragraph Empty the cooling system as described in the relevant paragraph Remove the exhaust system as described in the relevant paragraph Loosen clamps 1 and release engine from sleeves Loosen rear chassis upper pin 2 Undo and remove the two lower screws 3 from rear chassis Disconnect clamps 4 and remove intake manifold 5 from carburettor then turn subframe 6 ...

Page 63: ... a 10 mm ring wrench on the right side and a 12 mm ring wrench on the left side remove engine mount rear pins 11 With a 10 mm ring wrench on the right side and a 12 mm ring wrench on the left side remove engine mount front pin 12 Keep spacers and shims mark them so as to refit them in the same position Release engine from connectors by slightly turning it clockwise Slide engine out from the left h...

Page 64: ... removal Remove rear chassis as described in the relevant paragraph Remove filter with support 1 by pressing the retaining tab 2 Remove the four screws 3 securing filter box cover 4 TORX screws Using a 8 mm ring wrench remove the four screws 5 securing rear mud guard filter box 6 to subframe 7 Disassemble the different components ...

Page 65: ...fuel tank together with scoops and spoilers as outlined in the relevant paragraphs Drain coolant as described in the relevant paragraph Remove the plastic grids 1 from radiators by slightly bending them Undo pipe clamps 2 Disconnect pipes 3 from radiators 4 Loosen screws 5 and remove the two radiators 4 8 mm ring wrench ...

Page 66: ......

Page 67: ...F 1 F Ed 01 09 2010 ENGINE Section ...

Page 68: ...aft measurement 11 Operations on clutch cover 12 Water pump overhaul 13 Reed unit intake flange 13 Piston check 14 Piston ring gap measurement 14 Piston and cylinder measurement piston assembly clearance definition 14 Centrifugal clutch overhaul 15 Clutch wear compensation 16 ENGINE REASSEMBLY 17 Crankshaft and output shaft assembly 17 Primary drive assembly 17 Left hand crankcase half assembly 18...

Page 69: ...nown brands only A too low oil level or a poor quality oil lead to engine early wear and in the worst case even to irreparable damages to the engine itself Too much oil on the contrary results in high exhaust grad of smoke and soot deposits onto spark plug Should you wish to get a lean mixture proceed with extreme care by reducing jets by one number at a time in order to prevent piston overheating...

Page 70: ...at high rpm is controlled by main jet If engine runs with a 4 stroke cycle or at reduced power during acceleration with the throttle valve partially opened needle shall be lowered by one notch If engine knocks mainly during acceleration and close to high rpm needle shall be raised If the above described situations occur at reduced load lower rpm set a leaner mixture if engine gets wet and a richer...

Page 71: ...ne up again close fuel cock and allow engine to turn off by itself Then open the drain screw positioned onto carburettor tank to drain off also the remaining fuel Remove spark plug and pour approx 5 cc of engine oil inside cylinder through spark plug hole Operate kick start pedal 10 times in order to let engine oil be distributed on cylinder wall then refit spark plug Drain fuel from tank and coll...

Page 72: ...de pin 3 out of ignition coil remove cap from spark plug Loosen the 4 screws on intake flange 4 remove ignition coil with support intake flange and reed unit Remove spark plug Ignition cover removal Loosen screws 5 and remove ignition cover Water pump 6 is positioned outside onto ignition cover Ignition cover is centred thanks to two centring bushings that usually stay inside engine crankcase and ...

Page 73: ... out from top working with extreme care Position piston on the self manufactured wooden support Using a suitable tool remove piston pin snap ring 8 Separate piston pin from piston by hand remove piston and manually remove needle roller bearing from connecting rod Remove cylinder bottom gasket Rotor disassembly Lock rotor 1 with special tool 2 to prevent it from moving open and remove nut A shim po...

Page 74: ...alled separatecrankcasehalvesbyscrewingthejackingbolt At the same time gently tap crankcase with a plastic hammer to prevent output shaft 6 bearing from getting stuck Should output shaft bearing get stuck do not continue crankcase halves separation procedure You should first release any tension from crankcase by gently tapping it with a plastic hammer in order to prevent any damage to crankcase Se...

Page 75: ...e holes Bend output shaft nut lock washer 5 edge Loosen clutch nut and output shaft nut then remove screwdriver Remove nut with washer from crankshaft Using some M5x50 screws screw puller to centrifugal clutch 6 hold puller tight and slide centrifugal clutch out of crankshaft by screwing the jacking bolt Remove centrifugal clutch with bearing and shims from crankshaft Remove nut 7 and lock washer ...

Page 76: ...the crankcase at a temperature of 150 C you tap crankcase half on a flat wood board bearings usually come out of their seats spontaneously If necessary force bearings out of their seats Centring bushings shall always be removed first to prevent any damage to the crankcase The tools used to force new bearings into their seats shall be manufactured so as to lay just onto bearing outer ring nut Failu...

Page 77: ...side to the inside Force the new ball bearing fully home from the inside Crankshaft ball bearing protrudes approx 1 mm out of crankcase surface Output shaft ball bearing 4 With a suitable spindle press ball bearing from the outside to the inside Force the new ball bearing fully home from the inside Output shaft ball bearing is levelled with crankcase surface Crankshaft oil seal 1 Force and level t...

Page 78: ...hall be released Clean kick start pedal shaft and remove the old oil seal 5 with a suitable tool then replace it with a new one to be pressed inside its seat flush with the surface Upon reassembly push kick start pedal shaft inside clutch cover just enough to hook spring 6 and 7 Turn kick start pedal shaft counterclockwise to load spring and just after this operation you can fully install kick sta...

Page 79: ...to water pump shaft 4 Slightly grease water pump shaft at the sealing ring force it fully home with bearings inside ignition cover 9 and check for smooth motion Fit water pump impeller and circlip Fit cover 1 with a new O ring Refit spring 8 secure it with a bit of grease inside hole if necessary Reed unit intake flange Reeds loose their tensioning over time with a consequent power loss Damaged or...

Page 80: ...ton ring wear and gap Piston ring gap measurement Install ring inside cylinder and align it with piston approx 10 mm 0 39 in under cylinder upper edge Using a feeler gauge measure piston ring gap B Piston ring gap max 0 20 mm 0 0078 in Should gap be above the specified value check piston and cylinder for wear If piston and cylinder wear values are within tolerance change piston ring Piston and cyl...

Page 81: ...ove table Always make sure that an installation clearance of at least 0 045 mm 0 00177 in is present Centrifugal clutch overhaul Loosen TE screws 1 from clutch shoes 2 and remove them together with spring packs 3 from clutch hub 4 Remove TE screws with bushings and spring packs from clutch shoes Spring packs consist of 14 Belleville washers 5 which shall be over stacked as shown in the picture Bet...

Page 82: ...packbetweenclutchhuband shoes see figure If a single washer is assembled it can be used to this end Centrifugalclutchdruminnerdiametershallnotexceed84 4 mm 3 32 in 84 0 mm 3 31 in when new Whenevercarryingoutanymaintenanceorrepairworkonclutch make sure that spring packs are free from any dirt as serious failures may arise Reassemble all parts in the reverse order compared to disassembly TE screws ...

Page 83: ...nside bearings Connecting rod shall be positioned almost vertically Do not force the two shafts inside bearings using a hammer as this could result in bearings and crankshaft damage Primary drive assembly Insert key 1 inside output shaft keyway Install primary drive sprocket with the collar side 2 on output shaft Install nut lock washer Lock washer prong 3 shall engage inside primary drive sprocke...

Page 84: ... 0 Kgm 7 38 ft lb Tighten screws 8 9 10 to a torque of 10 Nm 1 0 Kgm 7 38 ft lb Using a plastic hammer gently tap crankcase at the bearings in order to release any tension Turn the two shafts to check that they move smoothly Using a sharp knife cut the protruding seal 11 flush with the edge To prevent any damage to oil seal wind some adhesive tape around output shaft square edge 1 Insulating tape ...

Page 85: ...trifugal clutch drum Fit centrifugal clutch Using a suitable screwdriver 7 lock centrifugal clutch drum and primary drive sprocket Lock crankshaft nut M10x1 25 with Loctite 243 and tighten to a torque of 35 Nm 3 5 Kgm 25 81 ft lb Tighten output shaft nut to a torque of 40 Nm 4 0 Kgm 29 50 ft lb Bend output shaft nut lock washer To ensure centrifugal clutch correct operation there shall be an axial...

Page 86: ...bushings 7x9x10 Align water pump control drive groove 2 with the corresponding mark 3 on crankshaft Make sure that spring is assembled inside water pump shaft Fit cover and turn it over with alternate motion until pump control starts engaging Do not attempt forcing ignition cover as some parts could be dam aged Screw ignition cover with the three TE screws TE M6x25 4 to the tighten ing torque of 1...

Page 87: ...piston pin retaining ring with the open side facing down Turn piston ring so as to make antitorsional piston ring engage inside piston ring opening 1 Fit cylinder bottom gasket compress piston ring by hand and install oiled cylinder onto piston If neither piston nor cylinder crankshaft engine crankcase have been changed you can use a gasket having the same thickness as be fore Working crossways ti...

Page 88: ...decrease it remove some of them Cylinder head assembly Position cylinder water fitting 1 shall be on intake side Use new sealing washers on cylinder head screws tighten cylinder head screws working crossways and in two steps to a torque of 15 Nm 1 5 kgm 11 06 ft lb Water pipe intake flange and ignition coil assembly Connect water pipe and tighten hose clip Fit reed unit and intake valve with a new...

Page 89: ...ug connect ignition cable keep spark plug still to ground naked point on engine and start engine with this procedure spark plug should release a very strong spark if spark plug does not release any spark disconnect spark plug cap from ignition cable keep it approx 5 mm away from ground and operate kick start pedal if now a spark is visible replace spark plug cap if even now no spark is visible hav...

Page 90: ...tors Use one of the spark plugs listed in the Technical Specifications Check connectors and seal them with silicone Engine misfires No fuel The installed spark plug has a wrong heat rating self ignition The engine intake is incor rect Clean fuel ducts check tank breather hose and clean fuel Use one of the spark plugs listed in the Technical Specifications Check cylinder and carburettor tightening ...

Page 91: ...surement conditions cold engine saddle and tank removed from bike all coupling contacts and ground connections without any corrosion for each measurement strongly press kick start pedal all the way down at least 5 times Check pulse transmitter charge coil on output signal unipolar connector 1 PositionpeakvoltageadapterRredpushrodontoconnector Sblackpushrod to ground and connector 1 disconnected fr...

Page 92: ...utomatic transmission Main bearings 2 ball bearings Connecting rod big end bearing needle roller bearing Connecting rod small end bushing needle roller bearing Piston rings 1 R piston ring MODEL CR 50 Carburettor type Dell Orto PHBG 19 Main jet 85 Main nozzle 260 AU Idle jet 48 Taper needle W9 Needle position 3 Open mixture adjuster screw 3 0 Throttle valve 60 Start jet 60 ORIGINAL CARBURETTOR SET...

Page 93: ...0x1 25 20 Nm Clutch hub nut M10x1 25 Loctite 243 35 Nm Cylinder head screw M6 Loctite 243 12 Nm TE screw clutch shoes M7 15 Nm Cylinder bottom nut M8 18 Nm Stator TCEI screw M5 Loctite 243 8 Nm Gearbox oil filling screw M16 5 Nm Oil drain screw M10 15 Nm Other engine screws M5 7 Nm Other engine screws M6 10 Nm Other engine screws M8 30 Nm ...

Page 94: ......

Page 95: ...I 1 I Ed 01 09 2010 FRONT SUSPENSION Section ...

Page 96: ...I 2 Ed 01 09 2010 FRONT SUSPENSION Front fork removal I 4 Fork spring specifications I 5 ...

Page 97: ...I 3 H02123 Ed 01 09 2010 FRONT SUSPENSION H06248 CR 50 SM 50 ...

Page 98: ... original 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 Remove the screw 1 and the brake line clamp on the left hand side Remove the brake calliper from the L H fork leg loosening the two retaining screws 2 Remove the front wheel as described in Section Y ...

Page 99: ... 3 that secure the fork legs to steering head and bottom yoke Remove the fork legs Refit fork legs and front wheel as described in Section Y Set height A back to original value Fork spring specifications Length 350 mm ø outer 26 mm ø inner 19 4 mm Constant K 0 2 Kgm ...

Page 100: ......

Page 101: ...J 1 J Ed 01 09 2010 REAR SUSPENSION Section ...

Page 102: ...REAR SUSPENSION Rear shock absorber J 3 Rear suspension J 3 Rear shock absorber removal J 4 Disassembling and servicing the swinging arm J 5 Servicing the swinging arm shaft J 7 Chain roller chain guide chain slider J 8 ...

Page 103: ... 50 ft lb Rear suspension The suspension of this motorcycle consists of a shock absorber and a swinging arm The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions Hydraulic damping is also adjustable using outer adjuster screws Periodically check all components for wear ...

Page 104: ... Using two 14 mm ring wrenches loosen nuts 1 on shock absorber pins leaving these latter in their seat Slightly lift rear wheel and remove lower pin 2 Remove upper pin 3 and shock absorber 4 Upon reassembly position spacer 5 again onto upper pint between shock absorber 4 and chassis 6 Upon reassembly insert upper pin 3 from the right to the left and the lower pin 2 from the left to the right ...

Page 105: ...he rear wheel is lifted from the ground Remove the secondary drive chain 1 and detach the rear brake line 2 from the swinging arm A 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 Remove the complete wheel C Remove shock absorber lower shaft 5 ...

Page 106: ...cket wrench on the right side remove nut 6 from swinging arm shaft 7 and then remove swinging arm A Check swinging arm shaft straightness and slide out spacer E Check roller cages D and spacer E for wear turn the bushing inside the roller cage if you feel any tightness or hear noise replace them TIGHTENING TORQUE FIGURES 5 6 80 Nm 8 Kgm 59 ft lb ...

Page 107: ...N Servicing the swinging arm shaft Check shaft taper using a dial gauge Place the shaft on two identical reference blocks Turn the shaft and move the dial gauge horizontally to determine the amount of distortion Service limit 0 30 mm ...

Page 108: ...ain slider Check the wear of the above mentioned elements and replace them when necessary Check the chain guide alignment and remember that a bent element can cause chain early wear In this case chain might unwrap from the sprocket 1 Chain roller 2 Chain guide 3 Chain slider ...

Page 109: ...L 1 L BRAKES Ed 01 09 2010 Section ...

Page 110: ...L 2 BRAKES Ed 01 09 2010 Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 ...

Page 111: ...quipped 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 112: ...60 mm Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter 140 mm Rear brake disc thickness when new 3 10 mm 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 to the sp...

Page 113: ...e the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL Remove retaining ring 1 Undo pin 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads taking care to correctly position clip 3 Screw pin 2 and refit retaining ring 1 Retaining ring 1 is a safety component thus make sure it is cor rectly installed If the abov...

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Page 115: ...M 1 M Ed 01 09 2010 ELECTRICAL SYSTEM Section ...

Page 116: ...M 2 Ed 01 09 2010 ELECTRICAL SYSTEM Wiring diagram M 3 Electrical components location M 4 Spark plug M 5 Handlebar switches M 6 Left hand switch M 6 IMPORTANT M 7 ...

Page 117: ...M 3 3 4 2 1 Ed 01 09 2010 ELECTRICAL SYSTEM 1 Alternator 2 Electronic transducer 3 Engine kill 4 Spark plug Wiring diagram ...

Page 118: ...09 2010 ELECTRICAL SYSTEM Electrical components location The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Transducer 2 positioned under fuel tank close to carburettor ...

Page 119: ...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 condi tion 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 home finger tight...

Page 120: ...FF Bk H02159 1 Ed 01 09 2010 ELECTRICAL SYSTEM Handlebar switches Measure continuity on the different switches using a meter Replace any part found to be faulty Left hand switch 1 Engine stop button POSITION COLOUR ...

Page 121: ... 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 HIGH PRESSURE WATER OR AIR JETS SHALL MUST NOT contact ELECTRIC PARTS ...

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Page 123: ...N 1 N Ed 01 09 2010 ENGINE COOLING Section ...

Page 124: ...N 2 Ed 1 09 2010 ENGINE COOLING Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 125: ...iator 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 The radiator cap 1 has a pressure relief position to ...

Page 126: ...irculation cooling system uses a centrifugal pump located to the left of the head and two down draft 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 Radiators to water pump lower pipe ...

Page 127: ... 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 due to shea...

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Page 129: ...W 1 W Ed 01 09 2010 SPECIAL TOOLS Section ...

Page 130: ...W 2 1 2 3 Ed 01 09 2010 SPECIAL TOOLS SPECIAL TOOLS HUSQUARNA PART No DESCRIPTION 1 8000 H4605 Rotor locking wrench 2 8000 H6011 Squish check foil 3 8000 H6012 Puller complete ...

Page 131: ...sing 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 cleaning the thr...

Page 132: ...taining nut M8 8 8 1 15 8000H3822 Saddle pillar upper retai ning screw M8 8 8 1 25 Z00043928 Saddle pillar upper locknut M8 8 8 1 25 Z00069056 Saddle pillar lower retai ning screw M8 8 8 2 25 1 Nm 0 73756 ft lb CHASSIS CODE DESCRIPTION SIZE CLASS OF MATERIAL Qty RATED TOR QUE Nm ACCEPT RES TORQUE Nm NOTES 61ND15062 Pushrod adjuster check nut M6 8 8 1 4 Z00044240 Lever ball joint retaining nut M6 8...

Page 133: ...NSION CODE DESCRIPTION SIZE CLASS OF MATERIAL Qty RATED TOR QUE Nm ACCEPT RES TORQUE Nm NOTES 8B00H2753 Swinging arm shaft M12 8 8 1 80 8A00A8421 Chain slider onto fork retaining screw with collar M5 1 4 ZH0067545 Rear chain guide fixing M6 8 8 1 4 Z00062730 Rear chain guide fixing M6 1 4 Z00061313 Rear chain guide nut M6 8 8 2 4 ZC0095305 Shock absorber to chas sis retaining screw M10 8 8 1 40 80...

Page 134: ...00A8421 Right hand rear side panel retaining screw with collar M5 2 4 8A00A8421 Left hand rear side panel retaining screw with collar M5 2 4 8A00A8421 Left hand rear side panel retaining screw with collar M5 3 4 8A00A8421 Left hand front panel re taining screw with collar M5 3 4 U00055134 Clip nut M5 2 4 8000A8423 Flap mud TEF nut M6 2 5 800046893 Flap mud clip nut M6 2 5 1 Nm 0 73756 ft lb FAIRIN...

Page 135: ...nt and rear wheel retaining nut M12 2 80 8000H4147 Chain tensioner adjuster screw M6 2 5 61ND15062 Adjuster nut and chain tensioner M6 2 5 Z00062731 Upper front brake calliper retaining screw M6 1 10 LOCTITE 243 ZPA067545 Lower front brake calliper retaining screw M6 1 10 LOCTITE 243 ZE0067545 Front rear brake calliper retaining screw M6 1 10 LOCTITE 243 Z00062727 Rear brake calliper rear retainin...

Page 136: ...AL Qty RATED TOR QUE Nm ACCEPT RES TORQUE Nm NOTES Z00062727 Damping pad to chassis retaining screw M6 2 10 Z00044240 Damping pad to chassis retaining nut M6 2 10 Z00062725 Damping pad to muffler retaining screw M6 2 10 Z00044240 Silencer retaining nut M6 1 10 Z00062729 Silencer retaining screw M6 1 10 U00060873 Silencer clip nut M6 1 10 EXHAUST CODE DESCRIPTION SIZE CLASS OF MATERIAL Qty RATED TO...

Page 137: ...b 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 Kgm 4 8 ft lb Steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb Steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb Steel screws on brass copper aluminium M8 16 Nm 1 6 Kgm 11 8 ft lb Steel screws on iron ...

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Page 139: ...Y 1 Y Ed 01 09 2010 CHASSIS AND WHEELS Section ...

Page 140: ...l 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 Tightening torque figures Y 11 Checking chain and sprockets for wear Y 12 ...

Page 141: ... with circular rectangular and ellipsoidal section the rear chassis is made from light alloy Refer to the figure for a quick inspection Use the dimensions reported below to determine whether the chassis needs realigning or replacing A badly damaged chassis must be replaced Lubrication points lubricant 1 Steering bearings grease ...

Page 142: ...SSIS AND WHEELS Front wheel Light alloy wheel hub and rim with high strength steel spokes Make type and size of wheel rims light alloy 1 5x12 Make type and size of tyre Pirelli Scorpion 60 100 12 36M Cold tyre pressure 1 2 Kg cm2 ...

Page 143: ...ne and see that the front wheel is lifted from the ground Loosen nut 1 positioned on left hand side Slide out axle 2 on right hand side and remove wheel Do not operate the front brake lever 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 ...

Page 144: ...as to set the brake disc into the calliper Fit the wheel axle 2 from the R H side after greasing it and push it fully home against the L H fork leg during this operation the wheel should be turned Screw nut 1 on fork left hand side 80 Nm 8 Kgm 59 lb ft After reassembly pull the brake control lever until the pads are against the brake disc ...

Page 145: ...ASSIS AND WHEELS Light alloy wheel hub and rim with high strength steel spokes Make type and size of wheel rim light alloy 1 6x10 Make type and size of tyre Pirelli Scorpion 2 75 10 37JNHS Cold tyre pressure 1 5 Kg cm2 Rear wheel ...

Page 146: ...n the chain 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 To reassemble reverse the above procedure remembering to insert the brake disc into the calliper Do not operate the rear brake pedal when the wheel has been re moved this causes the calliper pistons to move outwards After remova...

Page 147: ... 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 place Wheels ...

Page 148: ...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 Standard Max limit ...

Page 149: ... 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 six 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 150: ...et 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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