Husqvarna SMS 125 2011 Workshop Manual Download Page 26

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C.2

CR 125 2011 - WR 125 2011

TROUBLESHOOTING

Workshop Manual Ed. 06-2011

ENGINE

Trouble

Cause

Remedy

Engine does not start or has starting trou-

bles

Insufficient compression

1. Piston seized

Replace

2. Connecting rod small or big end seized

Replace

3. Worn piston ring

Replace

4. Worn cylinder

Replace

5. Cylinder head loosely tightened

Tighten

6. Spark plug loose

Tighten

Weak or no spark

1. Spark plug faulty

Replace

2. Fouled or wet spark plug

Clean or dry

3. Spark plug electrode gap too wide

Adjust

4. Ignition coil faulty (CR)

Replace

5. Faulty transducer (WR)

Replace

5. High-tension cables open circuit or shorted

Check

The carburettor is not receiving fuel

1. Tank cap breather clogged

Clean

2. Fuel cock clogged

Clean

3. Clogged fuel inlet hose

Clean

4. Floater valve faulty

Replace

5. Linkage is blocking floater valve

Release

Carburettor floods

1. High fuel level in bowl

Adjust

2. Floater valve worn or stuck open

Replace or release

Engine stalls easily

1. Fouled spark plug

Clean

2. Electronic control unit faulty (CR)

Replace

3. Faulty transducer (WR)

Replace

4. Carburettor jets clogged

Clean

5. Low idle

Adjust

Summary of Contents for SMS 125 2011

Page 1: ...CR 125 2011 WR 125 2011 Workshop Manual Ed 06 2011 ...

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 manual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 06 2011 ...

Page 3: ...LS COVERED from serial number onwards Copyright by HUSQVARNA MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop Manual 1 Chassis serial number TE 250 310 2011 I E CR 125 2011 WR 125 2011 CR 125 ZKH4H00AABV050001 WR 125 ZKH4H00AABV000001 ...

Page 4: ...customer s description of the problem and ask the appropriate questions to clearly identify problem symptoms diagnose the problem and identify the causes clearly This manual provides basic background information that must be supplemented with the operator s expertise and specific training available through HUSQVARNA held at regular periods plan ahead before starting work gather any spare parts and...

Page 5: ...neral information A Maintenance B Troubleshooting C Settings and adjustments D General procedures E Engine disassembly F Engine overhaul G Engine assembly H Front suspension I Rear suspension J Brakes L Electrical system M Engine cooling N Special tools W Tightening torque figures X Chassis and wheels Y NOTES Unless otherwise specified data and specifications apply to all models ...

Page 6: ......

Page 7: ...b 1 CR 125 2011 WR 125 2011 b Workshop Manual Ed 06 2011 IMPORTANT NOTICES Section ...

Page 8: ...th the engine at top rpm as in long distance road or highway travel Riding over long distances at full throttle may result in severe engine damage IMPORTANT VEHICLE CONFIGURATION as outlined below is a prerequisite for the war ranty to remain valid A STANDARD MOTORCYCLE FOR ROAD USE DERATED B COMPETITION MOTORCYCLE RACING USE with FULL POWER EN GINE In order to maintain the vehicle s Guarantee of ...

Page 9: ...A 1 CR 125 2011 WR 125 2011 A Workshop Manual Ed 06 2011 GENERAL INFORMATION Section ...

Page 10: ...tion A 3 Fuel system A 3 Primary drive A 3 Clutch A 3 Transmission A 3 Transmission ratio A 4 SECONDARY DRIVE A 4 FINAL RATIOS A 4 FRAME A 4 FRONT SUSPENSION A 4 REAR SUSPENSION A 4 FRONT BRAKE A 4 REAR BRAKE A 4 RIMS A 4 Tires A 4 Cold tire pressure A 5 Electrical components location A 5 Overall dimensions A 6 Weight A 6 Capacities A 7 ...

Page 11: ...tion Type electronic digital capacitor discharge type with variable advance Spark plug type CHAMPION QN 84 NGK BR9EG Spark plug gap 0 6 mm 0 0236 in Fuel system Type Carburettor Mikuni TMX 38 Venturi diameter mm 38 1 50 in High speed jet CR 460 High speed jet WR 380 Low speed jet CR 35 Low speed jet WR 15 Starting jet CR 80 Starting jet WR 50 Main nozzle R 8 914 Floater n 2 g 6 1 Throttle valve CR...

Page 12: ...cradle roud tubes light alloy rear frame FRONT SUSPENSION Type Upside down telescopic hydraulic front fork with advanced axle adjustable in compression and rebound stroke stanchions tubes Ø 1 89 in Legs axis stroke 300 mm 11 80 in REAR SUSPENSION Type progressive with hydraulic single shock absorber spring preload adjustment Wheel stroke 296 mm 11 65 in FRONT BRAKE Type fixed disc Ø 10 24 in Wave ...

Page 13: ... plug on cylinder head CR Electronic ignition coil under the fuel tank Electronic control unit positioned on left hand side under tank WR Transducer secured onto a bracket under fuel tank Voltage regulator secured onto a bracket close to transducer WR The electrical system includes the following elements Flashing indicator device under the fuel tank Headlamp with twin halogen bulb of 12V 35 35W an...

Page 14: ...ngth B CR mm 2215 87 2 in WR mm 2260 88 98 in Overall width C CR mm 820 32 28 in WR mm 840 33 07 in Overall height D WRE mm 1305 51 38 in WR mm 1300 51 18 in Saddle height E CR mm 985 38 78 in WR mm 975 38 39 in Minimum ground clearance F CR mm 325 12 08 in WR mm 315 12 04 in Weight Kerb weight without fuel CR 92 Kg 202 83 lb Kerb weight without fuel WR 96 Kg 211 64 lb ...

Page 15: ... Imp Gall 0 18 U S Gall Engine lubricating oil CASTROL A747 Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 10W 40 Engine coolant CASTROL MOTORCYCLE COOLANT Brake system fluid CASTROL RESPONSE SUPER DOT 4 Grease lubrication CASTROL LM GREASE 2 Final drive chain lubrication CASTROL CHAIN LUBE RACING Front fork oil KHL15 11 CR 352 cm3 WR 643 cm3 140 mm Electric contact protection CA...

Page 16: ......

Page 17: ...B 1 CR 125 2011 WR 125 2011 B Workshop Manual Ed 06 2011 MAINTENANCE Section ...

Page 18: ...Y S CONNECTING ROD ASSY S EXHAUST VALVE DRIVE REGULATOR C EXHAUST VALVE FORK S EXHAUST VALVE COUNTERSHAFT S EXHAUST VALVE CONTROL ROD S EXHAUST VALVE P TRANSMISSION OIL S S SET OF MATCHED PRIMARY C X CLUTCH DISCS HOUSING C X CLUTCH DISCS C X CLUTCH DISCS PRESSURE PLATE C X CLUTCH SPRING C X CLUTCH DISCS HOUSING C X CLUTCH DISENGAGEMENT ROD C X CLUTCH CONTROL SHAFT C X CLUTCH SPRING PLATE C X LEGEN...

Page 19: ...OLD C X RADIATORS C X COOLANT HOSES AND CLAMPS C X COOLANT C X FOOTRESTS FOOTREST PINS AND SPRINGS C X SADDLE FRAME FASTENING BOLTS ENGINE FASTENING BOLTS C C SIDE STAND C CHAIN GUIDE ROLLER BEARINGS C STEERING HEAD STEERING CROWN WITH PIN L FRONT FORK R HANDLEBAR HOLDERS AND FASTENING SET C C REAR SWING ARM BUSHINGS C REAR CHAIN SLIDER C X REAR SUSPENSION LINKS BUSHINGS C REAR CHAIN GUIDE REAR CH...

Page 20: ... power engine SCHEDULED MAINTENANCE CHART CHASSIS ITEM COUPON COUPON COUPON COUPON COUPON REPLACE IF NECESSARY AFTER FIRST 4 hours EVERY 4h CR 8h WR EVERY 8h CR 16h WR EVERY 16h CR 32h WR EVERY 32h CR 64h WR EVERY 40h CR 80h WR BRAKE PADS C X BRAKE SYSTEM PUMP CALIPER HOSES C FUEL HOSES C S X EXHAUST SILENCER PACK C X EXHAUST PIPE AND SILENCER C X WHEEL SPOKES TENSION C C WHEEL HUB BEARINGS S REAR...

Page 21: ...CONNECTING ROD ASSY S EXHAUST VALVE DRIVE REGULATOR C EXHAUST VALVE CONTROL ROD S EXHAUST VALVE C TRANSMISSION OIL S S SET OF MATCHED PRIMARY C X CLUTCH DISCS HOUSING C C X CLUTCH DISCS C X CLUTCH DISCS PRESSURE PLATE C C X CLUTCH SPRING C C X CLUTCH DISCS HOUSING C C X CLUTCH DISENGAGEMENT ROD C C X CLUTCH CONTROL SHAFT C C X CLUTCH SPRING PLATE C C X LEGEND C CHECK L LUBRICATE P CLEAN S CHANGE N...

Page 22: ...SES AND CLAMPS C X COOLANT C C X FOOTRESTS FOOTREST PINS AND SPRINGS C X SADDLE FRAME FASTENING BOLTS ENGINE FASTENING BOLTS C C SIDE STAND C C CHAIN GUIDE ROLLER BEARINGS C C STEERING HEAD STEERING CROWN WITH PIN L FRONT FORK R HANDLEBAR HOLDERS AND FASTENING SET C C REAR SWING ARM BUSHINGS C REAR CHAIN SLIDER C X REAR SUSPENSION LINKS BUSHINGS C REAR CHAIN GUIDE REAR CHAIN GUARD C C X REAR SWING...

Page 23: ...otorcycle street legal with limited power engine SCHEDULED MAINTENANCE CHART CHASSIS ITEM COUPON COUPON COUPON COUPON COUPON REPLACE IF NECESSARY AFTER FIRST 1000Km EVERY 1500 Km EVERY 3000 Km EVERY 7000 Km EVERY 10000 Km BRAKE SYSTEM PUMP CALIPER HOSES C X FUEL HOSES S X EXHAUST SILENCER PACK C X EXHAUST PIPE AND SILENCER C C X WHEEL SPOKES TENSION C C WHEEL HUB BEARINGS S REAR DRIVEN SPROCKET S ...

Page 24: ......

Page 25: ...C 1 CR 125 2011 WR 125 2011 C Workshop Manual Ed 06 2011 TROUBLESHOOTING Section ...

Page 26: ...dry 3 Spark plug electrode gap too wide Adjust 4 Ignition coil faulty CR Replace 5 Faulty transducer WR Replace 5 High tension cables open circuit or shorted Check The carburettor is not receiving fuel 1 Tank cap breather clogged Clean 2 Fuel cock clogged Clean 3 Clogged fuel inlet hose Clean 4 Floater valve faulty Replace 5 Linkage is blocking floater valve Release Carburettor floods 1 High fuel ...

Page 27: ...e Noise seems to come from gearbox 1 Worn gears Replace 2 Worn gear grooves Replace Noise seems to come from the secondary drive chain 1 Chain stretched worn or improperly adjusted Replace or adjust 2 Worn transmission sprockets Replace The clutch slips 1 Clutch adjuster screw with insufficient clearance Adjust 2 Weak clutch springs Replace 3 Worn clutch plates Replace The clutch is tight 1 Clutch...

Page 28: ...Carburettor main jet clogged or of the wrong size Clean or replace 7 Too much ignition advance Adjust 8 Deposits on the exhaust valve Clean 9 Exhaust valve wrongly installed Check Adjust The engine overheats 1 Dirty combustion chamber and or piston crown with carbon deposits Clean 2 Insufficient oil in engine or wrong oil Top up or change 3 Obstructions blocking air flow on radiator Clean 4 Cylind...

Page 29: ...ty too high Replace 3 Overinflated tyres Deflate 4 Improperly set rear shock absorber Adjust 5 The compression damping adjuster adjustment is too hard Adjust 6 Damaged bushing Replace 7 Bent slide pipe Replace Damping is too soft 1 Insufficient oil in fork legs Top up 2 Fork oil viscosity too low Replace 3 The fork spring free lenght is shorter than service limit Replace 4 Damaged damping valve Re...

Page 30: ...STEM see also Section M Trouble Cause Remedy The spark plug gets dirty easily 1 Dirty air filter Clean 2 Worn piston rings Replace 3 Worn piston or cylinder liner Replace 4 Mixture too rich Adjust carburettor Spark plug electrodes overheat 1 Spark plug electrode gap too close Adjust 2 Heat rating too high Replace with recommend ed spark plug 3 Mixture too lean Adjust carburettor Generator does not...

Page 31: ...D 1 CR 125 2011 WR 125 2011 D Workshop Manual Ed 06 2011 SETTINGS AND ADJUSTMENTS Section ...

Page 32: ...ir filter check D 16 Air filter cleaning D 16 Assembly D 17 Secondary drive chain adjustment D 18 Chain lubrication D 19 Disassembling and cleaning D 19 Washing a chain without O rings CR D 19 Washing the chain with OR WR D 19 Lubricating a chain without O rings CR D 19 Lubricating the chain with OR WR D 19 Suspension setup according to track condition D 21 Shock absorber adjustment D 22 Shock abs...

Page 33: ...D 3 CR 125 2011 WR 125 2011 H06664 CR 125 H06665 WR 125 Workshop Manual Ed 06 2011 SETTINGS AND ADJUSTMENTS ...

Page 34: ...the rear fixing 1 counter clockwise remove it and extract the saddle Tank removal Remove the saddle as described in the relevant paragraph Remove the screws 1 and the side panels 8 mm Allen wrench Remove the tank retaining screw 2 8 mm Allen wrench Slide out the breather hose 3 Release the clamp 6 close the cock 4 and disconnect the hose 5 ...

Page 35: ...D 5 CR 125 2011 WR 125 2011 H06672 7 Workshop Manual Ed 06 2011 SETTINGS AND ADJUSTMENTS Lift the front part of the tank 7 and remove it from the bike with the scoops ...

Page 36: ...r if register 2 should not provide sufficient movement to allow for correct adjustment then adjust register placed on carburetor There should be approx 1 mm play on latter register should this not be the case then loosen lock nut 3 and loosen or tighten screw 4 to respectively increase or decrease the play Operation with damaged throttle cable could result in an unsafe riding condition Idle adjust...

Page 37: ...crew the five screws 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 Remove the plates 8 lubricate the new plates with engine oil and install them always start with a friction plate Refit clutch actuator plate bearing and pressure plate Tighten the spring screws gradually in a cross pattern When refitting the clutch cover check gasket for we...

Page 38: ...n it in the direction indicated by the arrow A to decrease clearance turn it in the direction indicated by the arrow B to increase it There should be at least 10 mm 0 39 in free play V before the clutch begins to disengage The adjustment can be also effected with tightener 3 set on the left of the frame Take care to tighten properly the lock nut If the clutch slips under load or drags in disengage...

Page 39: ...e brake lines or the brake may be defective Check the system or proceed to drainage as outlined in the relevant paragraph Do not spill brake fluid onto any painted surface or light lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact ...

Page 40: ... free 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 5 mm free play B before the brake begins to bite Should this not happen operate as follows Loosen the nut 4 Operate the master cylinder linkage 5 to increase or decrease free play Tighten the nut 4 at the end of the ...

Page 41: ...as outlined in the relevant paragraph Do not spill brake fluid onto any painted surface or light lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Checking the...

Page 42: ...oosening the lower screws 2 and the side screws 3 On reassembly make sure the spacer 4 is correctly positioned To change oil unscrew the undersump cap 5 remove the cap 6 and let the oil drain completely then screw the cap back on with its seal and pour fresh oil through the filler hole Use only the prescribed quantity and type of oil Have this operation made with warmed up engine ...

Page 43: ... that it is perpendicular to the ground The coolant should be approximately 0 39 in above the cells The radiator cap features two locking positions the first one is for prior discharge of pressure from the cooling system 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 ...

Page 44: ...the right side of the vehicle under the water pump 1 Loosen the exhaust screw 2 using an 8 mm wrench Slowly open the RH radiator cap 3 and let the liquid drain After drain tighten the screw 2 replacing the aluminium sealing washer 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 oc...

Page 45: ...ant in the radiator then warm up the engine in order to eliminate any possible air bubbles Periodically check the connecting hoses see Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses A show cracks swelling or hardening due to sheaths desiccation their replacement shall be advisable Check the correct tightening of the clamps B ...

Page 46: ... chassis 6 Air filter cleaning Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEANER or similar then dry it fully wash filter with gasoline only in case of necessity Plunge the filter in special oil for filters CASTROL FOAM AIR FILTER OIL or similar then wring it to drain superfluous oil Do not use gasoline or a low flash point solvent to clean the element A fire or explosion c...

Page 47: ... on side facing filter housing While re inserting the filter into its housing make surs that piece A is turned up wards and edge B is on the left lower side of the filter case Reassemble the parts previously removed If the element assembly is not installed correctly dirt and dust may enter and the engine resulting in rapid wear of the piston rings and cylinder ...

Page 48: ...in figure A and then turn the rear wheel three turns In this condition the chain should be neither taut nor slack Fig A Quick adjustment Fig B Insert a 35 mm socket a or a shim of the same size at the position shown in the figure and check that the lower section C of the chain is slightly taut If it is not proceed as follows Loosen the wheel axle nut 1 on the right hand side using a 27 mm socket w...

Page 49: ...tha If you use fuel or especially trichloroethylene dry and lubricate the chain to avoid oxidisation Washing the chain with OR WR Wash using oil diesel oil or paraffin oil Never use gasoline tricloroetilene or solvents as the OR may suffer damages Use instead special sprays for chains with OR Lubricating a chain without O rings CR After drying dip the chain in Molybdenum Disulphide chain lubricant...

Page 50: ...act with the tyres or the rear brake disc Chain guide roller chain guide roller chain guide chain 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 ...

Page 51: ...cially harder rebound settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork set compression harder or replace the standard spring with a harder spring Shock absorber harder compression and rebound settings or replace the standard spring with a harder spring Work on the spring preload to lift the motorcycle riding height rear end Changing the spr...

Page 52: ...n 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 The shock absorber lowering should be of about 100 mm 5 To achieve correct rider sag for your weight adjust the spring preload of the shock absorber see relevant paragraph The shock absorber adjustment affects both the s...

Page 53: ...cycle 2 Clean lock ring nut 1 and adjuster ring 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 the lock ring nut firmly tightening torque 40 Nm 4 Kgm 29 50 ft lb Be careful not to touch hot exhaust pipe while adjusting the shock absorber Spring...

Page 54: ...setting turn upper adjusters 1 and 3 clockwise until reaching fully closed position Then turn them back the number of clicks speci fied above In order to obtain a smooth braking efficiency turn the adjusters counter clock wise Vice versa to obtain a harder braking action B REBOUND Standard setting 18 clicks 2 clicks To reset the standard setting turn lower adjuster 2 clockwise until reaching fully...

Page 55: ...kwise Vice versa to obtain a harder braking action REBOUND Fig b CR LOWER ADJUSTER WR TOP ADJUSTER CR 13 clicks WR 10 clicks To reset standard setting turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action BLEEDING Fig a b to ca...

Page 56: ... Push and pull in a front to rear motion to feel for play If any play is detected adjust as follows Loosen the steering head tube nut 1 loosen the two screws 3 securing steering head to fork legs Turn the steering head tube ring nut 2 clockwise using the special key until achieving correct play adjustment Tighten the steering head tube nut 1 to 80 90 Nm 7 9 Kgm 59 66 38 ft Ib Tighten the two bolts...

Page 57: ...the handlebar clamp bolts 3 and 4 and then remove the handlebar upper 1 and lower 2 clamps a Changing handlebar position Rotate the lower clamp by 180 to move handlebar position forward or back ward 10 mm 0 04 in b Changing handlebar height Remove the lower spacer A and replace the screw 4 with a 65 mm long screw When finished tighten the bolts 3 to 2 75 3 05 kgm 27 30 Nm 19 9 22 lb ft and the bol...

Page 58: ...they are cracked or hard ened they must be replaced 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 Remove the right hand side panel 3 and check the conditions of the silent block 4 If damaged replace them by loosening screws 5 8 mm wrench on the outside and 10 ...

Page 59: ...r B of a lever C pivoting on such shaft of a connection lever D and another control lever E pivoting on the valve control shaft With the valves fully closed the min distance from the piston must be equal to or over 0 4 0 5 mm 0 0157 0 0197 in To perform this adjustment proceed as follows Remove the cover 1 by loosening the screws 2 using an 8 mm wrench Loosen the screws 3 and 4 locking plate 5 in ...

Page 60: ......

Page 61: ...E 1 CR 125 2011 WR 125 2011 E GENERAL PROCEDURES Workshop Manual Ed 06 2011 Section ...

Page 62: ... system removal E 9 Fuel tank and scoop removal E 11 Scoop removal E 12 Spoiler removal E 13 Voltage regulator removal WR E 13 Transducer removal WR E 13 Coil removal CR E 14 Horn removal WR E 14 Number plate holder removal WR E 15 Front mudguard removal E 15 Rear brake removal E 15 Carburettor removal E 16 Chain slider removal E 18 Secondary drive chain removal E 19 Chain guard removal WR E 19 En...

Page 63: ...06 2011 Foreword 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 64: ...RES Workshop Manual Ed 06 2011 Engine guard removal Remove the engine guard 1 by loosening the lower screws 2 and the side screws 3 On reassembly make sure the spacer 4 is correctly positioned Saddle removal Turn the rear fixing 1 counter clockwise and remove the saddle ...

Page 65: ...hop Manual Ed 06 2011 Side panels removal Remove the saddle as described in the relevant paragraph Using an 8 mm wrench loosen retaining screws 1 and remove side panels 2 and 3 Electronic control unit removal CR Release connector 1 from control unit 2 Remove control unit 2 from the special vibration mount 3 ...

Page 66: ...rd and air box Remove saddle side panels tank silencer as outlined in the relevant para graphs Shear the plastic clips securing wiring to rear chassis WR Disconnect the connector 1 between main wiring harness and rear wiring harness WR Loosen clamp 2 securing filter box to carburettor Using a 10 mm wrench loosen screws 3 on both sides of chassis ...

Page 67: ...11 H06735 4 5 H06736 6 H06737 7 8 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Lift chassis 4 complete with filter box 5 Using an 8 mm wrench loosen the two inside screws 6 and the two side screws 7 and remove the filter box 8 ...

Page 68: ...6791 10 9 H02754 12 13 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Using an 8 mm wrench loosen the two screws 9 and remove shock ab sorber protection 10 Remove rivets 13 and remove upper rubber protection 12 Remove the air filter ...

Page 69: ...ove the saddle as described in the relevant paragraph Remove the right hand side panel as described in the relevant paragraph Using an 8 mm T wrench on the outside and a 10 mm T wrench on the inside remove the silencer 2 retaining screw 1 and remove it from the motorcycle KEY 1 Silencer 2 Rubber master link 3 Exhaust manifold 4 Springs ...

Page 70: ...shop Manual Ed 06 2011 Remove clamp 3 and disconnect secondary air circuit pipe 4 from exhaust manifold 5 Release the two springs 6 To remove manifold 5 loosen screw 7 with an 8 mm wrench Check seal 8 and metal gasket 9 for wear Change if damaged Check the rubber master link 10 for wear Change if damaged ...

Page 71: ...2 1 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Fuel tank and scoop removal Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the breather hose 1 Loosen tank retaining screw 2 with an 8 mm Allen wrench ...

Page 72: ... disconnect pipe 4 Raise the tank 6 from the front end and remove it from bike complete with scoops 7 Scoop removal Remove the saddle and side panels as outlined in the relevant para graphs Loosen front screw 8 between scoop 7 and tank Using an 8 mm wrench loosen screws 9 then remove right hand side scoop 7 Repeat this procedure for the left hand side scoop 10 ...

Page 73: ...move the left hand side 12 and right hand side 13 spoiler Voltage regulator removal WR Remove saddle and fuel tank as described in the relevant paragraphs Disconnect the connector 1 Loosen the retaining screw 2 and remove the regulator 3 8 mm wrench Transducer removal WR Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Disconnect the connector 2 Remov...

Page 74: ...d fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Using an 8 mm wrench loosen the retaining screws 2 and remove the coil 3 Horn removal WR Remove the headlamp fairing as outlined in the relevant paragraph Using an 8 mm wrench loosen screw 1 Disconnect the two connectors 2 and remove the horn 3 with its brack et ...

Page 75: ...Slide turning indicator cables out of rubber gaiter 3 Using an 8 mm wrench loosen screws 4 and remove number plate holder complete with turning indicators On reassembly make sure that number plate holder light cable 5 is positioned as shown in the figure Front mudguard removal Using an 8 mm wrench loosen the four screws 1 and remove mudguard 2 Rear brake removal Using a 6 mmAllen wrench loosen scr...

Page 76: ...06997 4 H06998 5 6 H06999 6 6 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Carburettor removal Close fuel cock 1 release clamp 3 and disconnect pipe 2 Loosen clamps 6 Cut the clamps 5 and disengage the breather hoses 6 from their holder clamps ...

Page 77: ...l Ed 06 2011 Slightly turn carburettor 7 to the left loosen the screws 8 and remove the cover 9 Detach carburettor 7 and remove it from the left hand side On reassembly take care that carburettor breather hoses 6 are cor rectly positioned inside their seats and that they are not kinked ...

Page 78: ...CEDURES Workshop Manual Ed 06 2011 Chain slider removal Remove the chain as described in the relevant paragraph Remove the circlip 1 and slide the sprocket 2 out Loosen the four screws 3 on the slider 4 using an 8 mm wrench Slide the chain slider out of the bike front side ...

Page 79: ... GENERAL PROCEDURES Workshop Manual Ed 06 2011 Secondary drive chain removal To remove chain proceed as follows Remove screws 1 sprocket guard 2 clip 3 master link 4 and chain 5 Chain guard removal WR Loosen screws 1 using an 8 mm wrench and remove the chain guard 2 ...

Page 80: ...e relevant paragraph Drain all coolant as described in the relevant paragraph Remove secondary drive chain as described in the relevant paragraph Remove rear brake pedal as described in the relevant paragraph Remove carburettor as described in the relevant paragraph Remove secondary drive chain as described in the relevant paragraph CR Release connector 1 from electronic control unit 2 WR Disconne...

Page 81: ...772 8 H06773 9 10 H06775 9 10 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Take off the spark plug cap 7 Disconnect the connector 8 of the power generator Open clamps 9 and disconnect the hoses 10 that connect the cooling system to the engine ...

Page 82: ...l Ed 06 2011 Lift retaining tab and disconnect clutch cable 11 Using a 12 mm wrench loosen the screws 12 of the left hand side bracket 13 of the head clevis and remove it Cut the clamp 14 and remove the left hand side protection 15 Cut the clamp 16 loosen the screw 17 using an 8 mm wrench and remove the protection 18 ...

Page 83: ...ging arm Using a 12 mm wrench on the left side and a 10 mm wrench on the right side loosen nuts 20 then remove engine retaining screws Slightly raise engine and remove it from bike left side Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs Drain all coolant as outlined in the relevant paragraph Using an 8 mm wrench loosen screws 2 and r...

Page 84: ...2 8 11 12 9 9 8 10 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Open clamps 5 and disconnect hoses 6 from right hand radiator 7 Open clamps 8 and disconnect hoses 9 from left hand radiator 10 Open clamp 11 and disconnect the radiator connecting hose 12 ...

Page 85: ...E 25 CR 125 2011 WR 125 2011 H06786 13 10 H07003 10 13 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Using an 8 mm wrench loosen screws 13 and remove left hand radiator 10 ...

Page 86: ...E 26 CR 125 2011 WR 125 2011 H06788 14 7 H06789 14 7 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Using an 8 mm wrench loosen screws 14 and remove right hand radiator 7 ...

Page 87: ... 1 1 2 3 3 GENERAL PROCEDURES Workshop Manual Ed 06 2011 Thermostat removal WR Remove fuel tank and drain all coolant as outlined in the relevant para graph Open the three clamps 1 securing the thermostat 2 Disconnect the hoses 3 and remove the thermostat 2 ...

Page 88: ......

Page 89: ...F 1 CR 125 2011 WR 125 2011 F ENGINE DISASSEMBLY Workshop Manual Ed 06 2011 Section ...

Page 90: ...sembly F 3 Clutch components F 4 Clutch side crankcase half component disassembly F 5 Sprocket side component and cover disassembly F 9 Intake valve disassembly F 12 Exhaust valve disassembly F 13 Piston cylinder and head assy disassembly F 14 Splitting the crankcase F 16 Gearbox removal F 16 Crankshaft removal F 17 ...

Page 91: ...sure that the two bushings 7 are correctly positioned Remove water pump cover 8 by loosening the retaining screws 9 10 and 11 Remove water pump impeller 12 by turning it by hand counter clockwise On reassembly take care that pump cover centring bushings 13 are positioned close to the two longer screws and replace gasket 14 Loosen the eight retaining screws 15 and 16 two and six pieces respectively...

Page 92: ...shop Manual Ed 06 2011 1 Screw 2 Washer 3 Spring 4 Pressure plate 5 Clutch assembly 6 Thrust washer 7 Needle roller bearing 8 Retainer 9 Ball 10 Pushrod 11 Clutch control shaft 12 Lock washer 13 Nut 14 Clutch hub 15 Washer 17 Clutch housing 18 Needle roller bearing 19 Spacer 20 Spacer 21 Washer Clutch components ...

Page 93: ...he relevant washers 2 and springs 3 Remove pressure plate 4 and clutch plates pack 5 from hub Slide thrust washer 6 axial roller bearing 7 and retainer 8 out of primary shaft end Tilt engine block on the right side and slide out ball 9 and pushrod 10 Working on the opposite side slide out clutch control lever 11 together with return spring and bushing Using a chisel and a hammer straighten the ben...

Page 94: ...his operation using special tool part no 8000 79015 with the ends inserted inside the two opposite grooves on clutch hub Lock clutch hub in place with tool and loosen locking nut 13 with a 22 mm socket wrench Slide nut 13 lock washer 12 and clutch hub 14 out of primary shaft end Slide washer 15 out of primary shaft ...

Page 95: ...06 2011 Crankshaft nut 16 has a left hand thread Loosen crankshaft nut 16 placing a 1 2 gear or an aluminium shim between clutch housing gear 17 and crankshaft gear 18 Slide clutch housing 17 the two needle roller cages 18 with spacer 19 the inner spacer 20 and three tab washer 21 out of primary shaft ...

Page 96: ... 22 H06801 26 ENGINE DISASSEMBLY Workshop Manual Ed 06 2011 Slide water pump control gear 22 and primary drive gear 23 out of crank shaft Remove the Woodruff key from crankshaft Slide selector shaft 26 out of right crankcase half rear side ...

Page 97: ...retainer on right crankcase half Working on the inner side slide out starter shaft assembly 28 complete with control gear and collect washer 29 Sprocket side component and cover disassembly Loosen the three retaining screws 1 and remove cover 2 Collect gasket Loosen the two retaining screws 3 on sprocket cover 4 and remove it to gether with the protective plate and spacers ...

Page 98: ...802 6 5 H06803 5 7 6 8 9 ENGINE DISASSEMBLY Workshop Manual Ed 06 2011 Remove circlip 5 and slide out sprocket 6 washer 7 spacer 8 and the OR gasket 9 NOTE On reassembly position the spacer 8 with the O ring seat 9 towards the inside ...

Page 99: ...g a 17 mm CR or 19 mm WR socket wrench loosen rotor sealing nut Remove lock washer Use the tool 7 part no 8000 60516 WR or 8000 46613 CR and secure it onto rotor Holding the tool in place with a 22 mm WR or 19 mm CR Allen wrench and working clockwise on the central screw remove rotor from crankshaft with a 14 mm WR or 17 mm CR Allen wrench ...

Page 100: ...ws 8 which fix the stator Remove the rubber cable run 9 and plate 10 for WR only from the left half casing then remove the stator Remove the Woodruff key from crankshaft Intake valve disassembly Using the special wrench part no 8000 98431 loosen the four sealing screws 1 on intake valve unit 2 Slide out the carburettor to valve fitting ...

Page 101: ...e valve 2 from crankcase and collect gasket 3 Exhaust valve disassembly Remove exhaust valve control unit 1 ad described in the relevant paragraph Loosen screw 2 and remove parts 3 4 5 and 6 Remove screws 7 and cover 8 Loosen grub screw 9 duly turn shaft 10 and remove if from its seat on cylinder Remove screws 11 and exhaust valves 12 ...

Page 102: ...t of the disassembly operations carried out so far The piston cylinder and head assy removal proves now necessary in order to separate the crankcase halves Loosen the five head sealing screws 1 on cylinder and collect the washer underneath Remove head 2 and collect the two outer 3 and inner 4 O rings NOTE The O rings between head and cylinder shall be changed upon each reassembly Loosen the four r...

Page 103: ...o not let it rotate as piston ring end could enter gaps thus preventing piston removal and causing damage to the piston ring itself To eliminate this risk removal operations shall be carried out with the piston at BDC Remove one of piston pin 7 retainers duly support piston and partially slide out piston pin using a cylindrical pin 8 until piston is free Remove piston 9 with piston pin Slide rolle...

Page 104: ...case half with 3 duly sized A screws work on the central pin and separate crankcase halves To make this operation easier tap output shaft end with a mallet while working with tool pin Remove shims from crankshaft primary shaft and selector shaft Gearbox removal Remove the two pins with shifter forks 1 Remove the two gearbox shafts 2 and 3 complete with gears at the same time To make this operation...

Page 105: ...alf use the same tool part no 8000 79016 already used for crankcase splitting Align tool holes with those on right crankcase half outer side and secure tool with three screws of a suitable length Duly support crankshaft and work on central pin to remove it When removing crankshaft never tap on its end even with a plastic hammer To remove bearing that will remain integral to the crankshaft on the l...

Page 106: ......

Page 107: ...G 1 CR 125 2011 WR 125 2011 G ENGINE OVERHAUL Workshop Manual Ed 06 2011 Section ...

Page 108: ...ler bearing replacement G 14 Oil seal replacement G 14 Clutch unit G 15 Friction plate thickness G 15 Friction plate to clutch housing clearance G 16 Clutch plate distortion G 16 Clutch spring G 16 Gear change G 17 Shifter forks G 18 Fork slider thickness G 18 Fork guide pin diameter G 18 Gear groove length G 18 Control shaft groove width G 19 Carburettor overhaul adjustment and maintenance G 19 C...

Page 109: ...s All parts must be cleaned with gasoline and dried with compressed air During this procedure flammable vapours develop and metal particles may be blown at high speed it is therefore recommended to perform this procedure away from open flames or sources of ignition and to wear goggles ...

Page 110: ...dicated in figure A d remove the piston and reassemble it on the connecting rod e reassemble the cylinder together with the head inserting the 0 5 mm seal on the crankcase f take the piston to the T D C and check that the reading on the dial gauge is equal to 1 2 mm 0 05 in figure B g should the reading be different restore the correct condition using a cylinder foot gasket of suitable thickness A...

Page 111: ...out of round value is 0 015 mm 0 0006 in In case of damages or excessive wear the cylinder shall be replaced Cylinders are marked by a letter or a colour referring to the class they belong to Cylinder measuring Check that the internal surface is perfectly smooth and free from scuffing Take the reading of the liner diameter DN 10 mm from the upper surface as indicated in the diagram towards the exh...

Page 112: ...cking or other damage The piston diameter D shall be measured 15 5 mm 0 61 in from the skirt bottom perpendicularly to the piston pin axis Standard Max size limit 1 02 1 04 mm 0 0401 0 0409 in 1 1 mm 0 043 in Clearances To ensure the best operating conditions and maximum performance all clearances must be within the specified tolerance A tight fit will lead to seizure as moving parts heat up where...

Page 113: ... bluing due to overheating Check the piston pin to piston clearance it shall be 0 002 0 009 mm 0 000079 0 000354 in Wear limit 0 012 mm 0 0005 in When replac ing the piston pin it is also necessary to replace the needle roller bearing cage in compliance with what specified in the paragraph piston pin piston connect ing rod small end clearance Cylinder Piston Abbreviation Size Abbreviation Size Cle...

Page 114: ... worn The piston ring should be positioned perfectly parallel to the groove surfaces in the piston Otherwise the piston shall be replaced Piston ring height The table shows the values of the axial clearance between lower upper piston ring and piston seat Piston ring to groove clearance Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taki...

Page 115: ...sary to measure the diameter A of the connecting rod small end and based on this value the proper needle roller bearing cage will have to be assembled NOTE When asking for the needle roller bearing cage specify the selection A connecting rod small end hole diameter colour selection mm in D piston pin diameter colour selection mm in B needle roller bearing cage diameter se lection White 18 998 19 0...

Page 116: ...iameter D of flywheel pin Based on these values assemble the suitable needle roller bearing cage NOTE When asking for the needle roller bearing cage specify the selection E connecting rod small end hole diameter colour selection mm in D pin flywheel connecting rod big end hole diameter colour selection mm in Needle roller bearing cage diameter selec tion White 30 014 30 016 1 1816 1 1817 Black 23 ...

Page 117: ...ng rod tests are meant to check its wholeness Should readings not comply with the max allowed wear limits it will be neces sary to replace it These tests can be carried out even with connecting rod assembled to crank shaft Big end axial clearance Connecting rod twist warping Standard Max wear limit 0 45 0 84 mm 0 0177 0 0331 in 1 1 mm 0 043 in Standard Max wear limit max 0 025 100 mm max 0 00098 i...

Page 118: ...eading Crankshaft Main journals should show no scoring or scuffing Threads keyways and splines must be in good condition Crankshaft straightness Standard Max wear limit less than 0 02 mm 0 00078 in 0 05 mm 0 0019 in To disassemble crankshaft use a support and suitable punches On reassembly comply with the specified tolerances Assemble the coupling pin into the flywheel halves with an oil having a ...

Page 119: ... each engine overhaul The main bearings shall always be removed in pairs and installed with the writing pointing out wards to replace them it is necessary to heat up the crankcase halves in a fur nace at 90 100 C and remove the bearing using a driver tool and a hammer Install the new bearing while the crankcase is still hot perfectly squarely with respect to the housing axis using the special inst...

Page 120: ...earing of the water pump shaft use special tool part no 8000 43824 Oil seal replacement Replace the oil seals at each engine overhaul To install the new oil seals in sert them squarely into their housings and use suitable driver tools After the assembly lubricate with engine oil the oil seal lip Carry out this operation with utmost care and attention ...

Page 121: ...utch components to make sure they are in the best conditions Clutch plates should show no signs of bluing scoring or distortion the plates fitted with friction material shall have a thickness complying with the values indicated in the table Friction plate thickness Standard Max size limit 3 mm 0 11 in 2 9 mm 0 114 in ...

Page 122: ... spring The free length of the clutch springs must not be smaller than the value indi cated below Standard Max wear limit Friction plate within 0 05 mm 0 0019 in 0 2 mm 0 0078 in Steel plate within 0 01 mm 0 0004 in 0 25 mm 0 0098 in Standard Max size limit 0 15 0 25 mm 0 006 0 010 in 0 35 mm 0 014 in Free check length Standard Max wear limit 42 5 mm 1 67 in 40 mm 1 57 in ...

Page 123: ...change Check that the gear front coupling teeth are in perfect conditions make sure that the idle gears rotate freely on their shafts and that their clearance is not higher than 0 10 mm 0 004 in The shaft threading and grooves must be in perfect conditions Moreover make sure that the gear selector components are in good conditions Check that the selector groove width complies with the specified to...

Page 124: ...ent fork will make gears hard to engage and let the transmission jump out of gear unex pectedly under loading Fork slider thickness Fork guide pin diameter Gear groove length Standard Max size limit 3 35 3 43 mm 0 132 0 135 in 3 31 mm 0 130 in Standard Max size limit 5 8 5 9 mm 0 228 0 232 in 5 75 mm 0 226 in Standard Max size limit 3 75 3 82 mm 0 148 0 150 in 3 9 mm 0 153 in ...

Page 125: ...enance The carburettor setting was determined by the manufacturer after performing extensive tests in a diverse range of condition of use it is therefore recom mended that no changes be made However if the motorcycle is used in particular environments it may be neces sary to change the initial setting The following chapters provide an overview of how the carburettor works as well as instructions t...

Page 126: ...lows are subject to precision operations and vary according to setting These parts belong to the three main circuits that supply mixture to the throttle valve openings These circuits are a IDLE CIRCUIT b OFF IDLE CIRCUIT c OPEN THROTTLE CIRCUIT 1 Taper needle 2 Throttle valve 3 Idle air screw 4 Main jet 5 Idle jet 6 Floater unit 7 Main nozzle 8 Throttle cable adjuster screw unit 9 Gasket unit ...

Page 127: ...ns below Idle jet The idle jet regulates the quantity of fuel that must be supplied to its circuit and is marked by an identification number that indicates its size The higher this number is the larger the diameter of the jet leading to a corresponding mixture enrichment Idle air screw The idle air screw regulates the quantity of air in the idle circuit by loosening or fastening this screw it is p...

Page 128: ...ng mixture enrichment Carburettor setting The concentration of oxygen in the air changes in relation to temperature al titude and humidity these elements therefore influence the setting of the car burettor Since the effects of humidity on oxygen concentration are negligible the two elements that must be taken into consideration are temperature and altitude Therefore the quantity of fuel to be mixe...

Page 129: ...nitial jet of 40 if the mixture is rich change to a jet of 35 conversely change to a jet of 45 For available jets see Parts Catalogue Open throttle circuit adjustment With an opening of the throttle control from 3 4 to maximum once the idle circuit has been adjusted perform the open throttle circuit adjustment by following the instructions above Before performing the off idle circuit adjustment ad...

Page 130: ...rform the adjustment by adjusting the groove of the taper needle retainer For available taper needles see Parts Catalogue Washer valve Make sure that plates are neither worn nor broken Should this be the case replace the plates and the plate stops When refitting the removed parts apply Loctite on the screws Exhaust valve Clean the valves with a spark plug cleaner brush or with thin sand paper Clea...

Page 131: ...H 1 CR 125 2011 WR 125 2011 H ENGINE ASSEMBLY Workshop Manual Ed 06 2011 Section ...

Page 132: ... 3 Generic fasteners H 4 Item summary and general assembly notes H 5 Crankshaft reassembly H 5 Gear shift part reassembly H 6 Piston cylinder and head reassembly H 10 Clutch reassembly H 13 Right cover reassembly H 15 Exhaust valve reassembly H 18 Exhaust valve position check H 18 ...

Page 133: ...tions and dimensions have been calculated for a certain operating life We recommend replacing the bearings especially those exposed to heavy loading also considering that checking them for wear is not an easy procedure These recommendations are in addition to the dimensional checks of individual components specified in the relevant section see Section ENGINE OVERHAUL Cleaning all components thorou...

Page 134: ... 1 1 1 3 1 1 1 2 6 4 3 1 1 3 5 2 5 1 6 1 4 4 1 6 1 5 1 3 1 M6 x 25 2 M6 x 20 3 M6 x 35 4 M6 x 45 5 M6 x 55 6 M6 x 8 1 M6 x 35 2 M6 x 20 3 M6 x 50 4 M6 x 65 5 M6 x 45 6 M6 x 16 ENGINE ASSEMBLY Workshop Manual Ed 06 2011 Generic fasteners ...

Page 135: ...nnecting rod big end Oil Piston Cylinder liner Spray oil Clutch housing roller bearing Oil Shaft gears Oil O rings Oil and grease Starter and gearbox drive shaft sleeves Molicote Mating parts Gearbox Molicote Engine sealing rings Grease Clutch drive shaft Grease Clutch pin and drive shaft Oil Cylinder head inner O ring Do not grease Dowel pin Oil or grease Centrifugal governor bearings Oil Exhaust...

Page 136: ... 0 012 015 in The Parts Office can supply shims having different thickness so as to achieve correct axial clearance Fit the original shims if removed parts are to be reassembled Fit the primary and output shaft at the same time inside the right crankcase half with the 1st 4th gear fork of the output shaft already inside its seat For correct gearbox operation check control dimensions shown in the f...

Page 137: ...the original shim 1 on primary shaft end Check the position of the centring bushings and place a new gasket on the right crankcase half Close the crankcase halves with the suitable retaining screws see relevant diagram 1 M6X35 screw No 5 pieces 2 M6X45 screw No 3 pieces 3 M6X50 screw No 2 pieces 4 M6X65 screw No 2 pieces Fit the selector shaft with its bearing and sector gear well lubricated with ...

Page 138: ...verheating and seizure When closing the crankcase halves check that they are perfectly aligned and correctly positioned Make sure that the crankshaft and the gear shafts can rotate freely in neutral Should these shafts not rotate correctly tap them with a rubber hammer to allow their correct settling Should this problem still occur open the crankcase halves again After closing the crankcase halves...

Page 139: ...tted between the rear end of the crankcase half and the protruding tooth D Pre charge the lever return spring by turning its end clockwise until it is fitted inside the special crankcase half hole Fit the selector shaft with spacer spring inside the crankcase half Position it so that the pin on the crankcase half can be inserted between the ends of the selector shaft spring and that the two pins o...

Page 140: ...inder bottom seal 1 Install the piston with its rings inside the connecting rod taking care that the arrow on the crown is pointing the exhaust Push the lubricated piston pin 2 into the piston by hand and lock it in place with its clips Lubricate all the parts to be assembled with engine oil and fit the cylinder into the piston by compressing the ends of the piston rings with your fingers or us in...

Page 141: ... slides freely inside cylin der Tighten the nuts 2 between cylinder and crankcase to the recommended torque working crossways Fit the duly greased external 3 and internal 4 O rings in the cylinder seats and insert the head inside cylinder stud bolts Working crossways lock head retaining screws 5 tightening them to the rec ommended torque ...

Page 142: ... 2011 WR 125 2011 H06969 1 3 2 ENGINE ASSEMBLY Workshop Manual Ed 06 2011 Fit the three stab washer 1 the inner spacer and the two roller cages 2 with the spacer 3 into the primary shaft Insert the clutch housing ...

Page 143: ...assembly Fit bushing spring and clutch control lever shaft inside L H crankcase half seat Fit the washer 1 and the disengagement group into the primary shaft in the following order the fist rod and the ball All these parts must be greased before reassembly Insert the clutch hub 2 in the primary shaft ...

Page 144: ...t no 8000 79015 lock the nut with a 22 mm socket wrench to the specified tightening torque Rivet washer onto nut Fit the friction plates starting by one of the seven line steel plates 3 and alternate it with one of the six friction plates 4 the last friction plate 3 will complete the pack Insert the spring retainer 5 and the axial needle roller bearing 6 on primary shaft end ...

Page 145: ...011 Fit the bearing thrust washer 7 and assemble the pressure plate 8 Fit the clutch springs 9 and lock them onto hub with the suitable washers and screws Right cover reassembly Install the original shim at the ends of water pump control shaft A and intro duce it inside its seat on RH crankcase half ...

Page 146: ...right hand side cover making sure that the ends of the water pump and centrifugal governor control shafts can be eas ily installed in their seats on the right hand side crankcase half Insert the eight retaining screws bearing in mind that the ones at the rear centring bushing white arrow are longer than the others Refit the centrifugal governor cover F Refit the clamp H then lubricate and refit th...

Page 147: ...pump control shaft end can be easily installed inside its special cover seat Insert the eight retaining screws taking care that the one at the rear centring bushing white arrow is longer than the other ones Moreover the oil pump pipe retaining bracket must be installed under the screw placed on top of the kick start lever Screw assembly diagram 1 M6X20 screw No 1 piece 2 M6X25 screw No 7 pieces 3 ...

Page 148: ...be equal to or grater than 0 4 0 5 mm 0 0157 0 0197 in On bushings A check the wear of the seats holes for pin B if worn replace the parts Once engine reassembly is over fit it back on the chassis resetting the origi nal and previously removed assemblies and cooling circuit connections Per form the necessary adjustments as described in section Settings and adjust ments Exhaust valve position check...

Page 149: ...I 1 CR 125 2011 WR 125 2011 I FRONT SUSPENSION Workshop Manual Ed 06 2011 Section ...

Page 150: ...I 2 CR 125 2011 WR 125 2011 FRONT SUSPENSION Workshop Manual Ed 06 2011 Front fork removal I 3 Front fork overhaul I 5 Front suspension CR I 5 Front fork disassembly CR I 6 Front suspension WR I 16 ...

Page 151: ...k removal Measure height A it will need to be restored to 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 screws 1 and the brake line clamp on the left hand side remove the six screws 2 and the fork leg guards ...

Page 152: ... calliper from the L H fork leg loosening the two retaining screws 3 remove the front wheel as described in Section Y loosen the bolts 4 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 ...

Page 153: ...wn telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Key 1 Bottom yoke with pin 2 Steering head 3 Nut 4 Compression valve 5 RH fork leg 6 LH fork leg 7 LH fork leg 8 RH fork leg 9 Ring nut 10 RH outer tube 11 Leg protection 12 Rebound adjuster screw 13 Retaining ring 14 Bushing 15 Bushing 16 Washer 17 Sealing ring 18 Retaining ring 19 Dust seal 20 Bushing 21 Bushin...

Page 154: ...actice to moderately slacken the cap nuts before remov ing the fork legs from the motorcycle Drain oil from the damper unit Clamp the wheel axle carrier in a vice and loosen the adjuster screw Push down the inner tube Slip the tool shown in the figure between wheel axle carrier and cartridge nut Hold the nut with a wrench and remove the adjuster screw Be careful not to hurt your fingers ...

Page 155: ...ut at the bottom end of the cartridge Remove the bottom valve assembly from the cartridge Hold the cartridge octagonal nut with the suitable tool to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Use a key to slacken the bottom valve assembly Check the O rings on the bottom valve assembly for damage Replace as required ...

Page 156: ...down and allow at least 20 minutes for oil to drain Remove the dust seal using a flat head screwdriver Remove the retaining ring using a flat head screwdriver Pull the inner tube until separating it from the outer tube To facilitate removal quickly but carefully pump the tubes back and forth until separating them Remove the sealing rings and the metal rings mounted on the inner tube ...

Page 157: ...bound adjuster Replace damaged O rings Replace the complete assembly do not reuse it Check the spring Replace it if outside diameter is damaged or exceedingly worn Free length is 454 mm 17 8 in or less Check the inner tube Replace if distorted Never attempt to repair or reuse a distorted fork tube If the tube shows surface defects sand the surface If repair is not possible replace the tube Never r...

Page 158: ...ng ring over the inner tube cover tube edge with plastic as shown in the figure This will avoid damage to the oil seal lip Fit metal bushing and washer to outer tube using an appropriate installer Fit the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure th...

Page 159: ...e Make sure that there is not play between dust seal and outer tube Refit the cartridge Tighten the nut all the way onto the rebound adjuster rod Make sure rebound adjuster rod thread length is at least 15 mm 0 6 in Fill the cartridge with the specified oil Pump the piston rod up and down repeatedly to remove any air from the cyl inder ...

Page 160: ...assembly With the bottom valve assembly installed check that the piston rod is fully extended Hold the cartridge octagonal nut to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Tighten the bottom valve assembly to 29 Nm 21 4 ft lb using a wrench Hold the cartridge with the piston rod end pointing downwards as shown in the figure Pump the piston rod up and ...

Page 161: ...he piston rod or any other parts Please note that excess oil may flow out from the hole located before the reservoir If you see no oil flowing out it means that there isn t enough oil in the car tridge Add oil to the cartridge before refitting it Drain excess oil from the reservoir Clean off any excess oil from the cartridge Install spring guide and spring on the cartridge Insert the cartridge int...

Page 162: ...eel axle carrier and cartridge nut Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw Be careful not to hurt your fingers Tighten the adjuster screw all the way in Make sure that there is some play between the bottom edge of the adjuster screw and the upper edge of the nut Tighten nut and adjuster to 28 Nm 20 6 ft lb using a wrench ...

Page 163: ...NSION Workshop Manual Ed 06 2011 Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm 40 5 ft lb Fill the outer tube with the specified quantity of oil 352 cm3 Tighten the cylinder onto the outer tube to 29 Nm 21 4 ft lb ...

Page 164: ...ront suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm Key 1 Bottom yoke with pin 2 Steering head 3 Nut 4 Cap unit 5 Ring nut 6 RH fork leg 7 LH fork leg 8 LH fork leg 9 RH fork leg 10 Leg protection 11 Damper unit 12 Bottom nut 13 Spring kit 14 LH RH outer tube ...

Page 165: ...he top of each outer tube it is good practice to moderately slacken the cap nuts before remov ing the fork legs from the motorcycle Loosen the fork cap nut and the nut with a wrench Remove top cap nut spring retainer spring and rebound adjuster rod Drain the oil Pump the piston rod up and down to drain oil from the cylinder ...

Page 166: ...R 125 2011 WR 125 2011 H06870 H06871 FRONT SUSPENSION Workshop Manual Ed 06 2011 Remove nut spring guide O ring and collar bushing Hold the cartridge top end steady Loosen and remove the bottom valve assembly ...

Page 167: ...I 19 CR 125 2011 WR 125 2011 H06868 H06869 FRONT SUSPENSION Workshop Manual Ed 06 2011 Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 168: ...he tubes back and forth until separating them Remove the sealing rings and the metal rings mounted on the inner tube Do not reuse any metal parts after removal Replace them with new components Replace damaged sealing rings Washer and retaining ring may be reused if they are not damaged Check the rebound adjuster rod for distortion or damage Replace as required Loosen and remove the bottom valve as...

Page 169: ...ace defects sand the surface If repair is not possible replace the tube Never reuse an inner tube if scored or showing bulges on the outer surface Check the outer tube Replace the tube is any distortion is detected or if the sliding surface is dam aged Mount sealing rings and metal parts on the inner tube See the figure below for the installation sequence Grease the edge of the sealing ring Before...

Page 170: ...the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring is fully seated in the groove inside the outer tube Fit the dust seal to the outer tube Make sure that there is not play between dust seal and outer tube ...

Page 171: ...25 2011 WR 125 2011 H06868 H06871 FRONT SUSPENSION Workshop Manual Ed 06 2011 Insert the cartridge into the outer tube Hold the cartridge top end into place Tighten the bottom valve assembly to 55 Nm 40 5 ft lb ...

Page 172: ...east an 18 mm 0 71 in portion of the rebound adjuster rod protrudes from the piston rod Oil filling Fill with the specified quantity of oil Fill the damper unit with the specified quantity of oil 643 cm3 Slowly pump the piston rod up and down to help oil reach all points of the cartridge If you haven t drained all oil from the damper unit on disassembly follow the procedure outlined below Filling ...

Page 173: ...down to help oil reach all points of the cartridge Add oil if level in the damper unit is too low Finally top up to the upper edge of the outer tube Allow the fork leg to rest until no more air bubbles can be seen then top up oil to specified level 140 mm below fork sleeve upper edge with maximum compression without spring Insert the rebound adjuster rod into the piston rod Insert spring and sprin...

Page 174: ......

Page 175: ...J 1 CR 125 2011 WR 125 2011 J REAR SUSPENSION Workshop Manual Ed 06 2011 Section ...

Page 176: ...ock absorber J 3 Lubrication points grease J 3 Rear suspension J 4 Rear shock absorber removal J 5 Disassembling and servicing the swinging arm J 6 Servicing the swinging arm shaft J 8 Servicing the rear suspension drop and drag link J 8 Chain roller chain guide chain slider J 8 ...

Page 177: ...J 3 CR 125 2011 WR 125 2011 H06892 1 H06891 2 REAR SUSPENSION Workshop Manual Ed 06 2011 Rear shock absorber TIGHTENING TORQUE FIGURES 44 49 Nm 4 4 4 5 Kgm 32 5 36 2 H Lb Lubrication points grease ...

Page 178: ...sing rate rear suspension is made up ofa shock absorber a linkage system 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 179: ...14 mm wrench on the right hand side and a 17 mm wrench on the left hand side loosen on the left hand side of the motorcycle the drag link 2 nut 1 and remove the pin 3 Using a 14 mm wrench loosen nut 4 Slightly raise rear swinging arm and remove shock absorber 6 lower pin 5 from the right side Using a 14 mm wrench loosen upper nut 7 then remove upper pin 8 and shock absorber 6 from the right side O...

Page 180: ...in 1 release rear brake line 3 from swing ing arm 2 and remove chain guard 4 WR as outlined in the relevant paragraphs see section E Remove rear wheel 4a as outlined in the relevant paragraph see section Y Using a 17 mm Allen wrench on the left side and a 14 mm Allen wrench on the right side loosen and remove drag link 6 pin 5 Using a 14 mm wrench loosen and remove shock absorber bottom retaining ...

Page 181: ...Workshop Manual Ed 06 2011 Remove plastic 8 by cutting clamp 9 and plastic 10 by cutting clamp 11 and loosening screw 12 Using a 22 mmm wrench loosen nut 13 on the left side and remove pin 14 on the opposite side Remove swinging arm On reassembly position nut 13 on the left side of motorcycle ...

Page 182: ...d 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 spacers and bearings for wear Grease the inner race of the bearings before refitting them Chain roller chain g...

Page 183: ...L 1 CR 125 2011 WR 125 2011 L BRAKES Workshop Manual Ed 06 2011 Section ...

Page 184: ...Braking system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 Removal of the rear braking system L 11 Removal of the front braking system L 12 ...

Page 185: ...s 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 ...

Page 186: ... Front brake disc thickness when new 3 0 mm 0 12 in Wear limit 2 5 mm 0 1 in Rear brake disc diameter 240 mm 9 449 in Rear brake disc thickness when new 4 0 mm 0 16 in Wear limit 3 4 mm 0 134 in Disc warpage must not exceed 0 15 mm 0 006 in 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 cleanallmatingsur...

Page 187: ...luid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL Remove clips 1 Slide out pins 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 The above procedure eliminates the need to bleed the braking system aft...

Page 188: ...he lever 3 repeatedly 5 Slightly tighten the bleed valve 1 and release the lever 3 6 Repeat steps 4 and 5 until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve 1 7 Top up fluid level A and refit rubber gaiter and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is ...

Page 189: ...he fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve 1 6 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 the procedure Fluid level inside the reservoir shall never drop below ...

Page 190: ...h 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 follows 1 Take the rubb...

Page 191: ...rate the brake lever 3 or the brake pedal 3A repeatedly until draining all fluid 5 Slightly tighten the bleed valve 1 or 1A and release the brake lever 3 or pedal 3A 6 Repeat steps 4 and 5 until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve 1 or 1A 7 Top up with fluid up to level A or B and refit rubber gaiter and reservoir cover After changing t...

Page 192: ...L 10 CR 125 2011 WR 125 2011 H06910 C H06911 D BRAKES Workshop Manual Ed 06 2011 Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 193: ...nual Ed 06 2011 Removal of the rear braking system Remove the rear wheel as outlined in the paragraph see chapter Y Remove the hose 2 supports 1 by loosening the screws 3 using an 8 mm wrench Loosen the two screws 4 and remove the pump 5 by disconnecting the microswitch connector 6 WR ...

Page 194: ...6 BRAKES Workshop Manual Ed 06 2011 Removal of the front braking system Remove the front wheel 1 as outlined in the relevant paragraph see sec tion Y Loosen the screws 3 and remove the block 2 Loosen the two screws 5 and disconnect the brake calliper 6 ...

Page 195: ...H06914 CR 7 8 H07014 9 H07013 8 7 BRAKES Workshop Manual Ed 06 2011 Release the hose 7 from the support 8 Disconnect the STOP microswitch connector 9 Loosen the two screws 10 6 mm wrench and remove the brake lever 11 complete with pump and tank ...

Page 196: ......

Page 197: ...M 1 CR 125 2011 WR 125 2011 M ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Section ...

Page 198: ... plug M 15 Timing curve M 16 Headlight unit with front fairing removal WR M 17 Removing headlight from front fairing WR M 18 Front turning indicator removal WR M 19 HEADLAMP TAIL LIGHT WR M 20 Headlamp adjustment WR M 20 Headlamp bulbs replacement WR M 20 Tail light replacement WR M 21 Number plate bulb replacement WR M 22 Rear turning indicator removal WR M 23 Rear wiring harness replacement WR M...

Page 199: ...SYSTEM Workshop Manual Ed 06 2011 Key to wiring diagram 1 Engine stop button 2 Spark plug 3 Coil 4 Control unit 5 Generator Colour coding key R Red Y Yellow B Blue G Green W White Bk Black P Pink V Violet Sb Sky blue Gr Grey O Orange Br Brown Wiring diagram CR ...

Page 200: ... 5 Front R H turning indicator 6 Headlamp 7 Front L H turning indicator 8 Rear stop light switch 9 Front stop light switch 10 Horn 11 Turning indicators flasher 12 Alternator 13 Voltage regulator 14 Rear L H turning indicator 15 Tail light 16 Rear R H turning indicator 17 Spark plug 18 Horn controller Colour coding key B Blue Bk Black Br Brown G Green Gr Grey O Orange P Pink R Red Sl Sky blue V Vi...

Page 201: ...011 Electrical component location CR The ignition system includes the following elements Generator 1 in oil bath on the inner side of L H crankcase cover Spark plug 2 on the cylinder head Electronic ignition coil 3 under the fuel tank Electronic control unit 4 positioned on left hand side under tank ...

Page 202: ...system includes the following elements Generator 1 in oil bath on the inner side of L H crankcase cover Spark plug 2 on the cylinder head Transducer 3 secured onto a bracket under fuel tank Voltage regulator 4 secured onto a bracket close to transducer The electric system includes the following elements Flashing indicator device 5 under the fuel tank ...

Page 203: ...0 9 ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Headlamp 6 with two filaments bulb of 12V 35 35W and parking light bulb of 12V 5W Back light 7 LED type Turn signals bulb 8 of 12V 10W Horn 9 and its control unit 10 positioned behind the front headlamp fair ing ...

Page 204: ...0 000 rpm positioned inside engine left side cover Measure across Red White and Black Red wires of the connector 1 correct value is about 25 5 If resistance is outside the specified limits replace the complete generator Generator performance RPM A D C typical 1000 5 8 1500 9 0 2000 10 9 3000 10 0 4000 8 0 5000 5 9 6000 4 0 AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS CAPTURED ...

Page 205: ...W at 10 000 rpm positioned inside engine left side cover Measure across the Brown and Black wires of the connector 1 correct value is about 0 75 If resistance is outside the specified limits replace the complete generator Generator performance r p m BTDC 1000 20 0 1500 9 0 2000 10 9 3000 10 0 4000 8 0 5000 5 9 6000 4 0 AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS CAPTURED BY T...

Page 206: ... voltmeter with a scale up to at least 50V Tester will show a certain voltage value 20V 50V If no value is shown or in case a great voltage unbalance is present across yel low cables then stator is faulty It will thus be necessary make a further check using an Ohmmeter measuring the insulation between the tested cable and ground This insulation shall be total i e with infinite resistance Electroni...

Page 207: ... 5 1 3 2 4 ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Electronic ignition system WR The electronic ignition system includes the following elements 1 12V generator 300W 2 Transducer 3 Voltage regulator 4 Spark plug 5 Engine stop button ...

Page 208: ... H02545 1 H06962 ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Voltage regulator The voltage regulator 1 converts the alternated current generated by the flywheel stator system into direct current at a constant voltage level of 12V ...

Page 209: ...gs with a meter Induction coil Primary winding resistance 4 5 15 at 20 C Secondary winding resistance 19 5 K 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resistance of the terminal cap contacting the spark plug Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specified limits replace the cap The area w...

Page 210: ... left side secured to a special bracket Electronic control unit ECU CR The control unit 1 is located on the left side under the fuel tank Capacitiveinjection i ethesparkonsparkplugisobtainedthankstothedischarge of a condenser positioned inside control unit through a capacitive coil Spark ignites based on an advance table relating to the RPM values ...

Page 211: ...before removing 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 i...

Page 212: ...M 16 CR 125 2011 WR 125 2011 H06975 CR H06976 WR ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Timing curve ...

Page 213: ...al WR Using an 8 mm wrench loosen screw 1 Move headlamp fairing 2 forward and lift it to release damping pads 3 from their mounts 4 Open pipe support 5 and slide out front brake pipe 6 and speed sensor cable 7 Disconnect headlight connector 8 and turning indicator connectors 9 On reassembly make sure that damping pads 3 are correctly installed inside supports 4 ...

Page 214: ... Manual Ed 06 2011 Removing headlight from front fairing WR Remove the headlight unit complete with front fairing as outlined in the relevant paragraph Loosen beam adjuster screw 1 Disconnect headlight connector 2 Widen the supporting tabs 3 and remove headlight 4 from the inside ...

Page 215: ...ing indicator removal WR Remove the headlight unit complete with front fairing as outlined in the relevant paragraph Disconnect connectors 1 and 2 of right and left turn indicators respec tively Using a 10 mm wrench on the inside and an 8 mm wrench on the outside loosen screws 3 and remove turning indicators 4 ...

Page 216: ... and the optical axis of the headlamp must be perpendicular to the wall the motorcycle must be upright measure the height from the ground to the centre of the lamp and draw a cross on the wall at the same height when the low beam is on the upper edge between dark and lit zone should be at 9 10th of the height of headlamp centre from ground Beam height can be raised or lowered turning the screw 1 H...

Page 217: ...shall not be touched with bare hands To replace the parking light bulb 5 extract it from the inside cover Once the bulb has been replaced reverse the above procedure to reassem ble Tail light replacement WR Remove the tail light as follows Loosen the two screws 1 under the rear mudguard Extract the tail light 2 and disconnect the connector 3 Once the bulb has been replaced reverse the above proced...

Page 218: ... Number plate bulb replacement WR Loosen screw 1 and remove the number plate bulb 2 from the mud guard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassem ble ...

Page 219: ...ator removal WR Remove the tail light as outlined in the relevant paragraph Disconnect connectors 1 and 2 of right and left turn indicators respec tively Slide turning indicator cables out of rubber gaiter 3 Using a 10 mm wrench on the inside and an 8 mm wrench on the outside loosen screws 4 and remove turning indicators 5 ...

Page 220: ...bar switches Measure continuity on the different switches using a meter Replace any part found to be faulty Left hand switch CR 1 Engine stop button Left hand switch WR The left commutator has the following controls 1 Engine stop button 2 HI Selection control High beam LO Selection control of Low beam 3 TURN Activation of left turn indicators self cancelling Activation of right turn indicators sel...

Page 221: ...8 G Bk Y G W W Bk B W Bk Sb R B Bk Gr G G Bk B ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Colour coding key B Blue Bk Black B Bk Blue Black G Green G Bk Green Black G W Green White Gr Grey Y Yellow R Red Sb Sky blue W White W Bk White Black ...

Page 222: ... Ed 06 2011 SEMICONDUCTOR PARTS Be careful to never drop parts that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage ...

Page 223: ... the instrument doesn t also show its functions To select the instrument functions and to set to zero the functions use the SCROLL knob A The instrument functions are the following as shown below 1 SPEED ODO figure 1 2 SPEED CLOCK figure 2 3 SPEED TRIP figure 3 4 SPEED CHRONO figure 4 1 SPEED ODO figure 1 1 SPEED Km h or mph ODO figure 1 SPEED motorcycle speed maximum value 299 Km h or 299 mph ODO...

Page 224: ...mum value 299 Km h o 299 mph TRIP 1 distance maximum value 999 9 km the data will be lost with voltage lower than 6V To setup the TRIP push the SCROLL A button holding down more than 3 seconds 4 SPEED CHRONO STP figure 4 SPEED motorcycle speedmaximum value 299 Km h o 299 mph STP 1 miles kilometers covered time Reading from 0 00 to 99 59 59 the data will be lost with voltage lower than 6V To activa...

Page 225: ...Ed 06 2011 Dashboard replacement WR Remove the headlamp fairing as outlined in the relevant paragraph Remove the two retaining screws 1 securing the dashboard to its bracket disconnect the connector 2 and remove the dashboard 3 To refit the dashboard reverse the disassembly procedure ...

Page 226: ...windings resistance 4 faulty spark plug cap see paragraph Checking coil windings resistance Positioning the connector Securing the wiring harness CR Generator connector 1 located under the fuel tank near the coil Electronic control unit connector 2 located on the left side of the chassis secured to a special bracket The wiring harness is secured to the chassis with clamps 3 The engine stop button ...

Page 227: ...e under headlamp fairing WR Front stop sensor connector 5 Speed sensor connector 6 Dashboard connector 7 Left hand switch connector 8 Turning indicator connector 9 Headlight connector 10 Horn connector 11 Control unit to horn connector 12 Rear WR Main wiring harness to rear wiring harness connector 13 Rear stop microswitch connector 14 ...

Page 228: ...H06984 17 18 16 ELECTRICAL SYSTEM Workshop Manual Ed 06 2011 Rear side under tail light WR Tail light connector 15 Number plate light connector 16 Rear right hand turning indicator connectors 17 Rear left hand turning indicator connectors 18 ...

Page 229: ...her dashboard switch generator the various available speed stop etc sensors and of a rear branch connecting tail light number plate light and rear turning indicators Main wiring harness 1 starts on bike front side passes through clip 2 slides along chassis slanted tube and is hold in place by clamps 3 Additional resistance 4 secured to the chassis with clamp 5 Routing of the rear brake cable 6 on ...

Page 230: ... Ed 06 2011 At the rear main wiring harness 1 is connected to rear wiring harness 7 which is secured with a clip 8 then it is secured with a clamp 9 to the chassis and with a plastic clip 10 On handlebar left hand switch and stop microswitch wiring harness is se cured on handlebar through rubber straps 11 ...

Page 231: ...N 1 CR 125 2011 WR 125 2011 N ENGINE COOLING Workshop Manual Ed 06 2011 Section ...

Page 232: ...N 2 CR 125 2011 WR 125 2011 ENGINE COOLING Workshop Manual Ed 06 2011 Coolant level check N 3 Cooling circuit CR N 4 Cooling circuit WR N 5 Engine cooling system overhaul N 6 ...

Page 233: ...der 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 The radiator cap 1 has a pressure rel...

Page 234: ...cuit CR The forced circulation 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 Head radiators upper pipe 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Water pump radiator lower pipe ...

Page 235: ...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 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Water pump radiator lower pipe 9 Thermostat to connection pipe 10 Thermostat 11 Thermostat to head pipe 12 Thermostat radiators upper pipe ...

Page 236: ...ator 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 ...

Page 237: ...W 1 CR 125 2011 WR 125 2011 W SPECIAL TOOLS Workshop Manual Ed 06 2011 Section ...

Page 238: ...ontrol tool CR 8000 86950 Ignition phase control tool WR 3 8000 89030 Crankcase bearing puller 5 8000 79015 Clutch hub tool 6 8000 79016 Crankcase half puller and crankshaft removal tool 9 8000 43824 Valve drive gear needle roller bearing water pump bearing and valve control puller 10 8000 43823 Oil pump shaft needle roller bearing puller 12 8000 98431 Anti tampering screw wrench WR ...

Page 239: ...rk itself 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 aft...

Page 240: ...4x0 7 3 0 3 2 0 29 0 33 2 1 2 4 Stator ret screw CR M6x1 8 8 9 8 0 9 1 0 6 5 7 2 Rotor lock nut M12x1 25 73 5 83 3 7 5 8 5 54 2 61 5 Spark plug M14x1 25 23 5 25 5 2 4 2 6 17 3 18 8 Clutch hub lock nut M16x1 27 4 30 4 2 8 3 1 20 2 22 4 Clutch spring ret screw M6x1 6 9 7 8 0 7 0 8 5 1 5 8 Gear shift control sector gear ret screw LOCTITE 270 M5x0 8 5 1 5 7 0 52 0 58 3 8 4 2 Ratchet bushing ret screw ...

Page 241: ...r brake lines ret screw M10x1 18 1 20 1 1 85 2 05 13 4 14 8 Rear stop switch WR M10x1 18 1 20 1 1 85 2 05 13 4 14 8 Front wheel axle ret screw M20x1 5 49 55 5 0 5 5 36 2 39 8 Fork leg retaining screw M8x1 25 23 5 25 5 2 4 2 6 17 3 18 8 Steering bearing adjuster ring nut 1st screwing M25x1 3 2 3 6 0 33 0 37 2 4 2 7 Steering stem nut M24x1 79 87 8 1 8 9 58 64 Brake pedal adjustment cam ret screw M6x...

Page 242: ...mper ret screw M8x1 25 21 6 23 3 2 2 2 4 16 17 3 Rear tank ret screw M6x1 10 3 11 3 1 05 1 15 7 6 8 3 Front brake disc ret screw M6x1 17 6 19 6 1 8 2 0 13 14 5 Front wheel axle ret screw M10x1 5 49 54 5 0 5 5 36 2 39 8 Brake calliper ret screw M8x1 25 23 3 26 5 2 4 2 7 17 3 19 5 Fuel cock ret screw ø 5 5 2 35 2 55 0 24 0 26 1 73 1 88 Saddle front ret screw M6x1 5 6 6 2 0 57 0 63 4 1 4 5 Air box re...

Page 243: ...uminium 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 steel M8 26 Nm 2 6 Kgm 19 1 ft lb...

Page 244: ......

Page 245: ...Y 1 CR 125 2011 WR 125 2011 Y CHASSIS AND WHEELS Workshop Manual Ed 06 2011 Section ...

Page 246: ...g the front wheel Y 6 Reassembling the front wheel Y 7 Speed sensor WR Y 8 Rear wheel Y 9 Removing the rear wheel Y 10 Wheel servicing Y 11 Wheel axle warpage Y 11 Axle runout over 100 mm Y 11 Wheel spokes Y 12 Wheel rim warpage Y 12 Rear chain sprocket secondary drive sprocket and chain Y 13 Tightening torque figures Y 13 Checking pinion and sprockets for wear Y 14 ...

Page 247: ...EELS Workshop Manual Ed 06 2011 Chassis 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 ...

Page 248: ...al Ed 06 2011 Lubrication points lubricant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS Chassis parts check ...

Page 249: ...6 2011 Front wheel LEGEND 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Seal 8 Bearings 9 Hub 10 Spacer 11 Brake Disc 12 Brake disc retaining screw 13 Circlip 14 Outer spacer 15 Pin retaining screw For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 250: ...ont wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out 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 251: ...ully home against the L H fork leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg ...

Page 252: ...Y 8 CR 125 2011 WR 125 2011 H02632 CHASSIS AND WHEELS Workshop Manual Ed 06 2011 Speed sensor WR Check the gap B between magnet 6 on brake disc and sensor 7 on brake calliper ...

Page 253: ...ear wheel KEY 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Spacer 8 Brake Disc 9 Seal 10 Circlip 11 Bearings 12 Inner spacer 13 Hub 14 Sprocket 15 Sprocket retaining screw 16 Wheel axle locking nut 17 Sealing ring For technical characteristics regarding the rear wheel see section A Gen eral Information of this manual ...

Page 254: ...necessary to loosen the chain tensioners 2 in this way the chain tension will remain unchanged 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 removed this causes the calliper pistons to move outwa...

Page 255: ... bearing 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 axl...

Page 256: ...metal tool 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 ...

Page 257: ...re at 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 six screws that retain it to the hub Chain and sprockets must always be replaced as a set Tightening torque figures 3 34 3 Nm 3 5 Kgm 25 3 ft lb LOCTITE 243 ...

Page 258: ...wn like the sprocket 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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