CR 125 WR 125

CR 150 USA

CR 125 2011
WR 125 2011
CR 150 2011 USA (EN)
CARATTERISTICHE - USO - MANUTENZIONE
SPECIFICATIONS - OPERATION - MAINTENANCE
CARACTERISTIQUES - UTILISATION - ENTRETIEN
Ed.00 - 09/2010

Dove non diversamente specificato, i dati e le prescizioni si riferiscono a tutti i modelli. MERKMALE - GEBRAUCH - WARTUNG
Unless specified, data and presciption are referred to all the models.
Lorsque non différemment indiqué, les donneé et les instructions se réfèrent à tous les modèles. CARACTERISTICAS - USO - MANTENIMIENTO
Wo nicht anders ausdrücklich angegeben, beziehen sich die Daten und die Vorschriften auf alle Modelle.
Donde no especificado, los datos y resenas se refieren a todos los modelos.

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ENGLISH

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PRESENTATION IMPORTANT NOTICES MOTOCROSS
Welcome to the Husqvarna motorcycling Family!
Your new Husqvarna motorcycle is designed and manufac- 1) The CR models are guaranteed COMPE-
tured to be the finest in its field. TITION motorcycles exempt from functional
The instructions in this book have been prepared to provide defects, the suggested maintenance table for
a simple and understandable guide for your motorcycle’s competition use is shown on Appendix A.
operation and care.
Follow the instructions carefully to obtain maximum per-
formance and your personal motorcycling pleasure. Your
owner’s manual contains instructions for owner care and
maintenance.
The main work of repair or maintenance requires the at- 2) WR vehicles are STREET LEGAL motorcy-
tention of a skilled mechanic and the use of special tools cles (with LIMITED POWER ENGINE); they are ENDURO
and equipment. guaranteed exempt from functional defects
Your Husqvarna dealer has the facilities, experience and origi- and covered with legal guarantee, if the
nal parts necessary to properly render this valuable service. STANDARD CONFIGURATION is maintained
This “Owner’s Manual” is part and par- and the suggested maintenance table, shown
cel of the motorcycle, hence, this had to on Appendix A (page A8) is observed.
remain with the motorcycle even when If WR vehicles are transformed in COMPETI-
sold to another user. TION MOTORCYCLES (with FULL POWER EN-
This motorcycle uses components designed thanks to sys- GINE), the suggested maintenance table for
tems and state of the art technologies which are thereafter competition use is shown on Appendix A.
tested in competition.
In competition motorcycles, every detail is verified after each
race in order to always guarantee better performance. For
correct functioning of the vehicle, it is necessary to follow the
maintenance and control table found on Appendix A.

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IMPORTANT maintenance plan, is charged to the client. Warning*: After an upset, inspect the motor-
NOTE: the guarantee is EXTINGUISHED in the cycle carefully. Make sure that the throttle,
The reference for recognition of the guarantee will be the MO- case where the motorcycle is rented. brake, clutch and all other systems are un-
TORCYCLE CONFIGURATION, as shown below: damaged. Riding with a damaged motorcy-

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cle can lead to a serious crash.
A) STANDARD MOTORCYCLE, STREET LEGAL: with LIMITED Important Notice
POWER ENGINE Read this manual carefully and pay special attention to state- Warning*: Never attempt to start or operate
B) COMPETITION MOTORCYCLE, RACING USE: with FULL POWER ments preceeded by the following words: your motorcycle unless you are wearing ap-
ENGINE propriate protective clothing. Always wear a
Warning*: Indicates a possibility of severe motorcycle helmet, motorcycle boots, gloves,
This motorcycles was not designed for long personal injury or loss of life if instructions goggles and other appropriate protective
trips with the engine always at maximum are not followed. clothing.
rpm as can occur whilst travelling on roads Caution*: Indicates a possibility of personal
or highways. Long trips at full throttle can injury or equipment damage if instructions Warning*: This motorcycle is a state of the
cause severe damage to the engine. are not followed. art competition bike. Do not attempt to start
This motorcycles is setup for competition use Note*: Gives helpful information. or ride this motorcycle until you have re-
and therefore guarantees maximum per- ceived expert instruction and are in excellent
formance with the rider alone. It is thereby physical condition.
not recommended to use the vehicle on cir-
cuits or off-road with a passenger.
Parts Replacement PRECAUTIONS FOR CHILDREN
ALWAYS keep in mind that these motorcycles have been de- When parts replacement is required, use only Husqvarna ORIGI- WARNING
signed strictly for competition use, that is, for conditions of NAL parts. • Park the vehicle where it is unlikely to
usage very different from those presented on the road. be bumped into or damaged. Even slight or
involuntary bumps can cause the vehicle to
ALWAYS keep in mind that these motorcycles topple over, with subsequent risk of serious
have been designed strictly for competition harm to people or children.
use, that is, for conditions of usage very dif- • To prevent the vehicle from tipping over,
ferent from those presented on the road. never park it on soft or uneven ground, nor
In order to maintain the vehicle’s “Guaran- on asphalt strongly heated by the sun.
tee of Functionality”, the client must follow •Engine and exhaust pipes become very hot
during riding. Always park your motorcy-
the maintenance program indicated in the
cle where people or children can not easily
user’s manual by carrying out maintenance
reach these parts, in order to avoid serious
checks at authorized HUSQVARNA dealers. burns.
The cost for substituting parts and for the
labour necessary in order to respect the

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TABLE OF CONTENTS Page Note
•References to the “left” or “right” of the motorcycle are in
PRESENTATION........................................................................ 2 the sense of a person facing forwards.
IMPORTANT NOTICES............................................................... 2
IDENTIFICATION DATA. ............................................................ 5 •Z: number of teeth
TECHNICAL DATA..................................................................... 7 • A: Austria
AUS: Australia
LUBRICATION TABLE, SUPPLIES................................................ 8
B: Belgium
CONTROLS. ............................................................................. 9
BR: Brazil
RIDING................................................................................. 16
CDN: Canada
IGNITION SYSTEM/ELETTRICAL SYSTEM............................. 44-46
CH: Switzerland
APPENDIX............................................................................. 47
D: Germany
PRE-DELIVERY INSPECTION. ................................................... 50 E: Spain
ALPHABETICAL INDEX. ........................................................... 51 F: France
PERIODIC MAINTENANCE -ADJUSTMENT.................... Appendix A FIN: Finland
GB: Great Britain
I: Italy
J: Japan
USA: United States of America

•Where not specified, all the data and the instructions are
referred to any and all Countries.

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IDENTIFICATION DATA
The engine number is printed on the upper side of the engine
case, whereas the frame number is printed on the steering tube. 1
Always state the number stamped on the frame

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(and write it on this booklet), when placing orders for spare
parts, or when asking for informations about your motorcicle.

FRAME NUMBER

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

2
The full 17-digit serial, or Vehicle Identification Number, is
stamped on the steering tube (R.H. side). CR 150 USA/CDN
(l) = Model designation
(▲) = Model Year (2011)
(♦) = Progressive no. 2 ZKH CR153# BV 000001

(l) (▲) (♦)

CR 125 WR 125

1 ZKH 4H00AA BV 050001 3 ZKH 4H00AA BV 000001

1. Frame serial number
2. Engine serial number
(l) (▲) (♦) (l) (▲) (♦)

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control location 10. Fuel cock
1. Front brake lever 11. Air bleeding screw on front fork leg
2. Throttle grip 12. Compression damper adjustment (front fork leg)
3- L.H. commutator (WR) 13. Extension damper adjustment (front fork leg)
4. Rear brake control pedal 14 .Rear shock absorber spring preload adjustment
5. Starting pedal 15. Rear shock absorber compression damper adjustment (low and high damping speeds)
6. Clutch control lever 16. Rear shock absorber extension damper adjustment
7. Fuel tank filler cap
8. Gearbox control pedal
9. Choke (L.H. side)

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 TECHNICAL DATA Starting jet (CR)...................................................................80 FINAL RATIOS
ENGINE Starting jet (WR)..................................................................50 1st gear .......................................................................29,258
Type.............................................. single cylinder, 2 stroke Main nozzle..............................................................R-8 (914) 2nd gear.......................................................................23,170
Cooling. ....................................................................... liquid Floater (n° 2)..................................................................g 6,1 3rd gear ......................................................................19,599

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Bore (CR/WR 125)......................................................2.13 in. Throttle piston (CR).............................................................4,0 4th gear........................................................................16,757
5th gear ......................................................................14,669
Bore (CR 150).............................................................2.28 in. Throttle piston (WR)............................................................5,0 6th gear ......................................................................12,412
Stroke. .......................................................................2.15 in. Metering pin................................................................ 6BFY43
Displacement (CR/WR 125)............................... 7.62 cu. in. Metering pin slot (CR)........................................................ 3rd FRAME
Displacement (CR 150)...................................... 8.79 cu. in. Metering pin slot (WR).......................................................2nd Type............................... Steel single tube cradle (roud tubes);
Compression ratio Idle mixture adjusting screw (CR).......................rounds 1+1/4 light alloy rear frame.
(with closed ports) (CR/WR 125)......................................8,8:1 Idle mixture adjusting screw(WR).......................rounds 1+1/2
(with closed ports) (CR 150).............................................8,6:1
FRONT SUSPENSION
Starting ................................................................. kick start PRIMARY DRIVE Type...................”Upside-down” telescopic hydraulic front fork
Drive pinion gear- Clutch ring gear .......................... Z 22- Z 71 with advanced axle (adjustable in compression and rebound
TIMING SYSTEM Transmission ratio . ........................................................3,227 stroke); stanchions tubes Ø 1.89 in.
Type..........lamellar valve on suction in the crankcase and Legs axis stroke........................................................11.8 in.
H.T.S. valve with mechanical control on the exhaust
CLUTCH
Type...... oil bath multiple disc clutch, mechanical control REAR SUSPENSION
LUBRICATION Type..............progressive with hydraulic single shock absorber
Engine . . . . . . . . . . . . . . . . . . . . . 4% (1:25) of oil-gasoline mix
during running in; NOT LESS than 3% (1:33)when running in is TRANSMISSION Wheel stroke.............................................................11.6 in.
over Type........................................ constant mesh gear type
Primary drive transmission/Gearbox . . by the oil contained in Transmission ratio FRONT BRAKE
the crankcase 1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,357 (z 33/14) Type.fixed disc Ø 10.24 in. “Wave” type with hydraulic control
2nd gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,866 (z 28/15) and floating caliper
IGNITION 3rd gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,579 (Z 30/19)
Type....... . . . . . . . . . . . . . . . . . . . . . . . . . . . electronic digital REAR BRAKE
capacitor-discharge type, with variable advance 4th gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,350 (Z 24/22)
5th gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,181 (Z 26/22) Type................................floating disc, Ø 9.45 in. “Wave” type
Spark plug type . . . . . . . . . . . CHAMPION QN B4/NGK BR9EG
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0236 in. 6th gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 (Z 21/21) with hydraulic control and floating caliper
RIMS
FUEL SYSTEM SECONDARY DRIVE Front......................................................in light alloy: 1,6x21”
Type.......................................... Carburettor “Mikuni” TMX 38 Transmission sprocket- Rear wheel sprocket . ........... Z 13- Z 50 Rear (CR)��������������������������������������������in light alloy: 2,15x19”
Venturi diameter............................................................1.5 in. Transmission ratio...........................................................3,846 Rear (WR-CR 150). . . . . . . . . . . . . . . . in light alloy: 2,15x18”
High speed jet (CR)............................................................460
High speed jet (WR)...........................................................380
Low speed jet (CR)...............................................................35
Low speed jet (WR)..............................................................15

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TYRES Fuel tank capacity, (1.32 Imp. quarts, 1.59 U.S. quart reserve TABLE FOR LUBRICATION, SUPPLIES
Front (CR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80/100x21” included) .................................. 1.54 Imp. gall., 1.85 U.S. gall.
Front (WR-CR 150) . . . . . . . . . . . . . . . . . . . . . . . . 90/90x21” Coolant capacity..................................0.97÷1.14 Imp. Quarts ,
Rear (CR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100/90x19” .............................................................1.16÷1.37 U.S. Quarts Engine lubricating oil
Rear (WR-CR 150). . . . . . . . . . . . . . . . . . . . . . . . 120/90x18” Transmission oil . . . . . . . . 0.70 Imp. Quarts , 0.85 U.S. Quarts CASTROL A747

Cold tire pressure Gearbox and primary drive lubricating oil

(front) (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8÷14.2 psi
( front) (%). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 psi CASTROL POWER 1 RACING 10W-40
rider and passenger
(rear) (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4÷12.8 psi Engine coolant
(rear) (%). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 psi CASTROL MOTORCYCLE COOLANT
(*) Racing use - (%) Road use Brake system fluid
CASTROL RESPONSE SUPER DOT 4
DIMENSION, WEIGHT, CAPACITY
Wheelbase (CR) ........................................................57.48 in.
Wheelbase (WR-CR 150) . ..........................................57.68 in. Grease lubrication
Overall length(CR).......................................................87.2 in. CASTROL LM GREASE 2
Overall length (WR-CR 150)........................................88.98 in.
Overall width (CR)......................................................32.28 in. Final drive chain lubrication
Overall width (WR-CR 150).........................................33.07 in. CASTROL CHAIN LUBE RACING
Overall height (CR) ...................................................51.38 in.
Front fork oil
Overall height (WR-CR 150) ......................................51.18 in. KHL15-11
Saddle height (CR).....................................................38.78 in.
Saddle height (WR-CR 150)........................................38.38 in.
Minimum ground clearance (CR)................................12.79 in. Oil for rear shock absorber
Minimum ground clearance (WR-CR 150).....................12.4 in. CASTROL SYNTHETIC FORK OIL 5W
Kerb weight, without fuel(CR). . . . . . . . . . . . . . . . . . . 202.8 lb Electric contact protection
Kerb weight, without fuel(WR). . . . . . . . . . . . . . . . . . . 211.6 lb CASTROL METAL PARTS CLEANER
Kerb weight, without fuel(CR150). . . . . . . . . . . . . . . . 206.8 lb
Fillers for radiator
AREXONS TURAFALLE LIQUIDO

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 CONTROLS A fuel filter is incorporated in the fuel valves. Accumulation of SIDESTAND
dirt in the filter will restrict the flow of the fuel to the carbure- A sidestand (1) is supplied with every motorcycle.
FUEL COCK tor. Therefore, the fuel filter should be serviced periodically.
To service:

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The cock (1) set on left side of tank has three positions: WARNING*: The stand is designed to sup-
OFF - closed; no fuel outlet; 1- Drain the fuel from the fuel tank. Disconnect the fuel line. port the weight of the MOTORCYCLE ONLY. Do
ON - open; fuel outflows from the main flow; 2- Remove the fuel valve by removing the screws. Wash the fuel not sit on the motorcycle using the stand for
RES - reserve; fuel outflows from the reserve flow. screen filter in cleaning solvent. support as this could cause structural failure
When running, should feed problem ensue, set cock lever on RES 3- Reassemble the fuel valve in the reverse order of removal.
position. After filling up, take the cock in ON position again. to the stand and could cause serious bodily
Turn the fuel valve “ON” and check for leaks. injury.
WARNING*: Be careful not to touch the hot
engine while operating the fuel valve. WR: Periodically check the side stand (see “Periodical mainte-
nance card”); check that the springs are not damaged and that
the side stand freely moves. If the side stand is noisy, lubricate
the fastening pivot (A).

1. Fuel cock
A. To carburettor

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FUEL CARBURETOR CHOKE
The motorcycle is equipped with 2 stroke engine that requires The starter knob (1), located on the left side of the carburetor, is
a gasoline-oil mixture. Recommended fuel: premium grade un- used to enrich the mixture during the engine start.
leaded fuel (R.O.N. 98). Pull out the knob to open the starter, and pull the lever upwards
to close it.
Note*: Do not continue operation if the en-
gine pings or knocks. The engine will be
damaged and could seize.

WARNING*: If “knocking” or “pinging”

occurs, try a different brand of gasoline or
higher octane grade.

WARNING*: Gasoline is extremely flamma-

ble and can be explosive under certain con-
ditions. Always stop the engine and do not
smoke or allow flames or sparks in the area
where the motorcycle is refueled or gasoline
is stored.

WARNING*: Do not overfill the tank. After re-

fueling, make sure the tank cap (2) is closed
securely.

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DIGITAL INSTRUMENT, WARNING LIGHTS (WR) - The instrument functions are the following, as shown below. 1- SPEED (Km/h or mph) / ODO (figure 1)

The motorcycle is equipped with a digital instrument; on the 1- SPEED / ODO (figure 1) - SPEED: motorcycle speed- maximum value: 299 Km/h or 299
instrument are located 2 warning lights too: high beam and 2- SPEED / CLOCK (figure 2) mph;

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blinkers. 3- SPEED / TRIP (figure 3) - ODO: odometer- maximum value: 99999 km;
4- SPEED / CHRONO (figure 4)
1- BLUE warning light “HIGH BEAM” 1- SPEED / ODO (figure 1) To replace kilometers with miles or miles with kilometers pro-
2- GREEN warning light “BLINKERS” ................. ceed as follows:
The instrument display illuminates (amber colour) when the 1) set to figure 1, stop the engine and push the knob SCROLL
engine started. (A);
2) Start the engine holding pushed the button SCROLL (A) until
NOTES the symbol “Km/h” will be displayed;
- Every time the engine starts, for the first 2 seconds, the 3) then the symbols “Km/h” and “Mph Miles” will be displayed
instrument shows the version of the checking SW; after the alternatively. Push again the SCROLL (A) button when the
check, the instrument shows the last planned function. unit you wish to use is displayed.
- When the motorcycle engine is OFF, the instrument doesn’t
also show its functions.
- To select the instrument functions and to set to zero the
functions, use the SCROLL knob (A).

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2- SPEED / CLOCK (figure 2) 3- SPEED / TRIP 1 (figure 3) 4- SPEED / CHRONO (STP) (figure 4)
- SPEED: motorcycle speedmaximum value: 299 Km/h o 299 - SPEED: motorcycle speedmaximum value: 299 Km/h o 299 - SPEED: motorcycle speedmaximum value: 299 Km/h o 299
mph; mph mph;
- CLOCK: clock- Reading from 0:00 to 23:59:59; - TRIP 1: distance- maximum value: 999.9 km (the data will be - STP 1: miles/kilometers covered time;
To reset the clock, push the knob SCROLL (A) for more than 3 lost with voltage lower than 6V). - Reading from 0:00 to 99:59:59 (the data will be lost with
seconds in order to increase the hours; release the knob and To setup the TRIP, push the SCROLL (A) button holding down voltage lower than 6V).
then, after 3 seconds, it is possible to increase the minutes; more than 3 seconds. To activate the function STP 1, push the knob SCROLL (A) for
more than 3 seconds.
- 1st step: function ON;
- 2nd step: stop to the counters;
- 3rd step: STP 1 zero-setting; TRIP 1 and AVS 1 data zero-
setting;
- 4th step: function ON;
- 5th step: stop to the counters;
.............................
and so following

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THROTTLE CONTROL STEERING LOCK (WR)
The throttle knob (1), is located on the right hand side of the The motorcycle is equipped with a steering lock (1) on the R.H.
handlebar. The position of the throttle control can be adjusted side of the steering head tube.

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by loosening the two fastenig screws . To lock it, procede as follows: turn the handlebar leftwards,
place the key in lock and turn counterclockwise. Push the key
inwards (if necessary, turn to and from). Turn the key clockwise
CAUTION and remove it from the lock.
Do not forget to tighten the screws (A) after To unlock the steering lock, reverse the above procedure.
the adjustment.

FRONT BRAKE CONTROL

The brake control lever (2) is located on the right hand side of
the handlebar. The position of the throttle control can be ad-
justed by loosening the two fastenig screws .

CAUTION
Do not forget to tighten the screws (B) after
the adjustment.

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HANDLEBAR COMMUTATOR (WR) ENGINE STOP BUTTON (CR) CAUTION
Do not forget to tighten the screws (C) after
On the left side of the handlebar, near the clutch control, is lo-
The left commutator has the following controls: cated the engine stop button (1). the adjustment.
1) Engine stop button ( ) A: To decrease clearance
CLUTCH CONTROL
The clutch lever is located on the left-hand side of the handlebar B: To increase clearance
2) HI = ( ) Selection control High beam
and is protected against dirt filtering in. The lever support is
LO = ( ) Selection control of Low beam provided with adjusting screw (1) to regulate clutch wire free
play. The clutch REAR BRAKE CONTROL
3) TURN lever can be adjusted to suit your driving position. The rear brake control (1) is placed on the right-hand side of
= Activation of left turn indicators (self cancelling) the motorcycle. On models WR a stop switch, during the braking
= Activation of right turn indicators (self cancelling) action, causes the rear light to come on.
To deactivate the indicator, press the control lever after
its returning to center.
4) HORN = ( ) Warning horn
5) LIGHTS

= Lighting control of lowbeams and high beam.

= Lighting control of position lights.

1
= Off

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GEAR SHIFT CONTROL KICKSTART PEDAL
The lever (1) is placed on the left-hand side of the engine. The The kickstart pedal (2) is situated on the right-hand side of the
operator must release the lever after each gear change to allow motorcycle.

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it to return to its central position before another gear change
can be made.
Neutral position (N) is between first (low) and second gears.
First gear is engaged by pushing the lever downwards; all the
other gears are engaged, by pushing the lever upwards.
The position of the gear shift lever on the shaft can be varied by:
loosening screw; pulling lever out; placing lever in new position
on the shaft when the operation is over tighten the screw and
then tightening the screw.
CAUTION*: Do not shift gears without disen-
gaging the clutch and closing the throttle. The
engine could be damaged by “overspeed”
and shock.
WARNING*: Do not downshift when traveling
at a speed that would force the engine to
overrev in the next lower gear, or cause the
rear wheel to lose traction.

N: Neutral

1 2

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RIDING 8. Check exhaust system 2. Stop the engine, and let it cool down naturally until its tem-
Check hook up, look for cracks perature is equal to the ambient air temperature. This will allow
BEFORE EVERY RIDE MAKE FOLLOWING CHECKS Check muffler. the piston to align itself to any imperfections which might exist
WARNING! 9. Check torque at the cylinder wall.
Before each ride, to prevent accidents or failures during ride, A. Spark plug (see page 23). 3. Repeat steps 1 and 2. (Do not ride the motorcycle).
make sure to go through following list. B. General check of torque 4. Bring the engine up to normal running temperature. Ride the
10. Check steering action motorcycle approximately 10 minutes at moderate speeds. Then
1. Check all fluids Check bearing play. repeat cool down procedure.AVOID HARD ACCELERATIONS.
A. Transmission oil level 11. Check the electric system (WR). 5. Bring engine up to normal temperature. Ride motorcycle
B. fuel level Start the engine and check that the front and rear lamps, the approximately 15 minutes at moderate to high speeds. Again
C. coolant level stop light, the turn signals the cluster warning lights and the avoid hard accelerations.
Make sure all caps are properly adjusted. horn are working correctly. 6.Repeat cool down procedure.
WARNING*: Don’t remove radiator cap when 7. Full throttle operation must be avoided until the engine has
hot! reached operating temperature, even after the break in process
2. Check all controls WARNING*: Failure to perform these checks is completed. When the above procedure is followed correctly,
A. Throttle handgrip every day before you ride may result in se- engine durability and performance will be greatly enhanced.
B. Clutch lever rous damage or a severe accident.
Make sure cables are not damaged and turn smoothly. CHECKS WHILE RUNNING IN
3. Check brakes
Look for brake fluid leaks and worn hoses. Check for proper When running in, the following should be checked out:
functioning. - WHEELS SPOKES TENSION;
4. Check suspensions - TIGHTENING OF WHEELS;
Compress fork and rear suspensions. Look for oil leaks and - FORK PIN TIGHTENING;
ensure proper functioning. - CHAIN ADJUSTMENT;
RUNNING IN - STEERING BEARING PLAY;
5. Check wheels
Check spokes and look for worn bearings. - HANDLEBAR TIGHTENING;
To obtain the best settling of the engine moving elements, for - ENGINE GRIP TO FRAME;
Check rims and tyres. driving your motorcycle to the best of your capability, run in the
Check tyre pressure. - SUCTION FITTING GRIP;
engine for several hours, following these procedures: - HEAD AND CYLINDER NUTS GRIP.
6. Check chain rollers and sprockets 1. FROM STOP POSITION. Start the engine and run at idle, but
Check wear on chain rollers and sprockets open the throttle periodically and briefly until the engine is tho-
Ensure chain is correctly adjusted and lubricated. Note*:
roughly warmed up. Within 3-4 minutes the coolant temperature After break in, install a new spark plug and
7. Check air filter and intake system will have reached approximately 60° C/140° F. (Do not ride
Check that air filter is clean change the transmission oil.
the motorcycle). After running-in, check that vehicle nuts and
Check all rubber connections and clamps.
bolts are properly tightened.

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ENGINE START IMPORTANT NOTE IN CASE OF COLD STARTS IMPORTANT
For the correct start of a cold engine proceed as follows: AT LOW TEMPERATURES Never accelerate the engine after a cold start.
- shift the transmission into neutral; It is recommended to briefly warm-up
- set fuel valve (1) in ON position; the engine at idle until, after having WARNING*: Exhaust contains poisonous car-

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- lift the knob lever (3) on the carburetor. disengaged the starter, there is a nor- bon monoxide gas. Never run the engine in a
Leaving the throttle in closed position operate kick-start (4). mal response from the engine when closed garage or in a confined area.
Take the knob lever in its initial position as soon as the engine opening the throttle.
is idling. This will enable the lubricant to reach
When starting with an already warmed up engine DO NOT USE
the starter. You can start the engine with the gear inserted, after the correct working temperature there-
by guaranteeing a correct functioning of WARNING*: This high performance motor-
disconnecting of the clutch. cycle can some times «kick back» strongly
If the carburetor is flooded, shut off the fuel supply and the all engine parts.
starter and operate the crank lever or the kick-start until the Avoid overheating the engine. when you are starting it.
engine starts. If necessary, remove the spark plug and dry it. Do not attempt to start this motorcycle unless
you are wearing high top heavy sided rid-
ing boots. You could seriously hurt you leg
if the kickstarter kicked back and your foot
slipped.

4
3

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STOPPING THE MOTORCYCLE AND THE ENGINE - Press the engine stop button (3). - Close the fuel cock (4).

- Close the throttle (1) completely so that the engine will help When the bike is off, place it on its side stand.
slow down the motorcycle.
- For normal braking, gradually apply both front and rear
brakes while down shifting (for maximum deceleration, ap-
ply the front and rear brakes firmly).
- When stopped, pull the clutch lever and shift gear lever (2) in
neutral position.

CR
1

WR
3
2 4

­18
TRANSMISSION OIL LEVEL CHECKING TRANSMISSION OIL CHANGE COOLANT LEVEL CHECK
A. Transmission oil level To completely replace the oil, unscrew the plug (A) under the Check level (1) in right-hand radiator when engine is cold (place
Keeping the motorbike level and in a vertical position, check oil sump and let oil come out, then screw the plug again with its the motorcycle so that it is perpendicular to the ground). The

EN
the oil level through the inspection (1) window on the right gasket and pour fresh oil from the hole of the loading plug. coolant should be approximately 10 mm above cells.
crankcase. Check if level (a) is about midway of the inspec- Use only the prescribed quantity and type of oil (see on page
tion porthole. 8) The radiator cap is provided of two unlocking positions, the
To fill up, remove the filler cap (2). first being for the previous pressure discharge in the cooling
Note: system.
Note*: Have this operation made with warmed-up Have this operation made with warmed-up
engine. engine. WARNING
WARNING*: Be careful not to touch hot Avoid removing radiator cap when engine
engine oil A: Draining plug is hot, as coolant may spout out and cause
scalding.

NOTE
Difficulties may arise in eliminating coolant
from varnished surfaces. If this occurs, wash
off with water.

­19
REPLACEMENT OF COOLING FLUID WARNING*: Coolant on tires will make them
slippery and can cause an accident or injury.
The cooling liquid replacement must be performed with cold
motor, as follows:
- remove the R.H. radiator plug; Periodically check the connecting hoses (see “Periodical main-
- remove the drain screw (2) on the pump cover or the pump tenance card”): this will avoid coolant leakages and consequent
cover by loosening the three screws (1); engine seizure: If hoses show cracks, swelling or hardenings due
- slope the motorbike on the right, to make the liquid come out to sheats desiccation, their
easily; replacement shall be advisable. Check the correct tightening of
- let the liquid drain completely; the clamps.
- reassemble the drain screw or the pump cover;
- pour the necessary quantity of liquid in the radiator (page 8);
- warm up the motor in order to eliminate any possible air bub-
ble;
- fit the motor in vertical position and check that the liquid in
the radiators must be 10 mm/0.4 in. over the radiant mas (if
not, top it up);
- screw the R.H. radiator plug.

­20
THROTTLE CABLE ADJUSTMENT - if register (2) should not provide sufficient movement to IDLING ADJUSTMENT
allow for correct adjustment, then adjust register placed on
The throttle cable can be adjusted using the screw set on the carburetor. Idling should be adjusted only when the engine is hot and throt-
throttle, or using the adjusting screw set on the There should be approx. 1 mm play on latter register; should tle is closed, as follows:

EN
carburettor cover. To check for proper adjustment of throttle this not be the case, then loosen lock nut (3), and loosen or - turn idle adjusting screw (1) so as to increase rpm (turn
cable, proceed as follows: tighten screw (4), to respectively increase or decrease the clockwise to increase rpms, counterclockwise to decrease rpm);
- remove rubber cap; play. - turn fuel mixture adjusting screw (2) clockwise or anticlockwi-
- move transmission sheath to and fro to ensure a play of ap- se until engine runs smoothly;
prox. 1 mm; - gradually loosen screw (1) to ensure that engine runs pro-
- should play be greater than 1 mm, loosen lock nut (1) and WARNING*: Operation with damaged throt- perly.
register (2); should play less than 1 mm, then tighten lock tle cable could result in an unsafe riding
nut and register; condition. WARNING*: Exhaust gas contains poisonous
carbon monoxide gas. Never run the engine
in a closed area or in a confined area.

­21
CLUTCH ADJUSTMENT The adjustment can be also effected with tightener (1) set on
the right of the frame. Take care to tighten properly the lock
The clutch is adjusted by stretching the cable using the adjusting nut. If the clutch slips under load or drags in disengaged posi-
unit positioned on the handlebar. tion after play has been
As a rule it is sufficient to operate on the handlebar register to adjusted, it must be taken apart for inspection. For this opera-
restore the clearance due to the flexible transmission stretch. tion apply to a Dealer.
The control lever must always have an empty stroke (C)
(3 mm) before starting clutch disengagement. To adjust this
clearance, act on register (2) after taking out rubber cap (1);
turn the register in the direction indicated by arrow A to reduce
the clearance (C); turn it in the direction indicated by arrow B to
increase the clearance.

1. Adjusting screw
1. Rubber cap 2. Locknut
2.Adjusting screw 3. Rubber cap

­22
SPARK CONTROL Correct heat rating: Before refitting the plug, thoroughly clean the
The tip of the insulator should be dry and the colour should be light electrodes and the insulator using a brass-metal
Use NGK BR9EG or CHAMPION QN84; spark plug (2); the gap brown or grey. brush.
is 0,6 in. High heat rating: Apply a little graphite grease to the spark plug

EN
A wider gap may cause difficulties in starting engine and in In this case, the insulator tip is dry and covered with dark deposits. thread; fit and screw the spark plug by hand
overloading coil. Low heat rating: then tighten to the torque of 23,5÷25,5 Nm-
A gap that is too narrow may cause difficulties when accelerat- In this case, the spark plug is overheated and insulator tip is vitre- 17,3÷18,8 ft/lb.
ous, white or grey in colour. Spark plugs which have cracked insulators or
ing, when idling the engine or when performing at low corroded electrodes should be replaced.
speeds. CAUTION*: Select a spark plug with a colder or
Clean the dirt away from the base of the spark plug before re- hotter heat range carefully and cautiously. A
moving it from the cylinder after removing the cap (1). spark plug with too hot a heat range may lead
It is very useful to examine the state of the spark plug just after it to preignition and possible engine damage. A
has been removed from the engine since the deposits on the plug spark plug with too cold a heat range may foul
as the result of too much carbon buildup.
and the colour of the insulator provide useful indications.

VOLTAGE REGULATOR (WR)

Voltage regulator (1) is secured onto a special plate positioned
under fuel tank.

2
­23
AIR FILTER CHECK AIR FILTER AND CLEANING ASSEMBLY
Turn rear pin (1) counterclockwise, remove the saddle from the Wash the filter with a specific detergent (CASTROL FOAM AIR To ensure tight fit, slightly (C) grease filter edge on side facing
front afstening screw. FILTER CLEANER or similar) then dry it fully (wash filter with filter housing.
gasoline only in case of necessity). While re-inserting the filter into its housing, make surs that
Remove screw (3) and the filter (4). Separate filter (5) from Plunge the filter in special oil for filters (CASTROL FOAM AIR piece (A) is turned upwards and edge (B) is on the left lower
frame (6). FILTER OIL or similar) then wring it to drain superfluous oil. side of the filter case. Reassemble the parts previously removed
(battery: connect the positive cable first).
CAUTION*: Do not use gasoline or a low flash-
point solvent to clean the element. A fire or CAUTION*: If the element assembly is not
explosion could result. installed correctly, dirt and dust may enter
and the engine resulting in rapid wear of the
CAUTION*: Clean the element in a well ven- piston rings and cylinder.
tilated area, and do not allow sparks or
flames anywhere near the working area.

4 6 A

3
5 C B
­24
STEERING WHEEL BALL PLAY ADJUSTMENT Stand in front of the motorcycle and grasp the lower end of
the fork rods sliders moving them in the direction of their axis.
To ensure maximum safety, the steering wheel should always Se si avverte gioco occorrerà eseguire la regolazione operando
be regulated so that the handlebars steering the motorcycle come segue:

EN
rotate freely without play. To check steering wheel adjustment, - loosen steering sleeve nut (1).
place kick stand or other support under the engine so that the - Loosen four screws that fix steering head to fork rods (3).
front wheel is raised from ground. Turn the steering ring nut (2) clockwise of the steering sleeve
Place slight pressure on the tips of the handlebars to rotate steer- proper tool, to adjust play properly.
ing wheel; the handlebars should also rotate without effort. - Tighten steering sleeve nut (1) to a torque setting of 57,9÷65,1
Lb/ft; (78,4÷88,3 Nm).
- Tighten four screws on the steering head (3) to a torque of
22,5÷26,5 Nm (16.6÷19.5 Lb/ft).

CAUTION*: Do not ride a motorcycle with

damaged steering stem bearings. An unsafe
handling condition can result.

3 1

2
­25
ADJUSTMENT OF THE CONTROL LEVER AND A decrease of the fuel level will let air into the sustem, hence CAUTION*: Do not spill brake fluid on to any
CHECK OF THE FRONT BRAKE FLUID LEVEL an extension of the level stroke. painted surface or lenses.
CAUTION*:Do not mix two brands of fluid.
The adjuster (2), located on the control lever, allows adjusting WARNING*: If the brake lever feels mushy Change the brake fluid in the brake line if
of the free play (a). when it is applied, there may be air in you wish to switch to another fluid brand.
Free play (a) must be at least 3 mm (0.1 in.). the brake lines or the brake may be CAUTION*: Brake fluid may cause irritation.
The level of the fluid in pump reservoir must never be below defective. Since it is dangerous to operate Avoid contact with skin or eyes. In case of
the minimum value (1), which can be checked from the window the motorcycle under such conditions, have contact, flush thoroughly with water and call
on the rear side of the pump body. the brake checked immediately by an a doctor if your eyes were exposed.
authorized HUSQVARNA dealer.

A: to encrease clearance
B: to decrease clearance

1 2
+ A

B -
­26
REAR BRAKE PEDAL POSITION ADJUSTMENT Rear brake idle stroke adjustment CHECKING THE FLUID LEVEL
The position of the rear foot brake pedal as to the footrest may The rear brake foot pedal should have a (B) 5 mm (0.2 in.) idle The level (A) must be set between the pump tank notches.
be adjusted according to the individual needs. For the adjusting stroke before starting the true braking action.

EN
proceed as follows:
- loosen the screw (1); Should this not happen, operate as follows:
- turn the cam (2) in order to adjust the brake pedal idle stroke - loosen nut (3);
(A); - operate the pump rod (4) to increase or decrease the idle stroke;
- the operation done, tighten the screw (1). - tighten nut (3) at the end of the operation.

The adjusting operation carried out, adjust the idle stroke of the WARNING
pedal as follows.. When the idle stroke figures are not met, the
brake pads will be subjected to a fast wear
that may bring to the TOTAL BRAKE INEFFEC-
TIVENESS.

1 4 A
2 3
­27
ADJUSTING THE SUSPENSIONS ACCORDING TO SANDY GROUND NOTE:
PARTICULAR TRACK CONDITIONS Fork: have a harder compression adjustment, or replace the When the fork results as either too soft or too hard for any ad-
standard spring with a harder one, and make a softer compres- justment conditions, check the oil level inside the forkrod.
The following information is a useful guide for setting up the sion adjustment and a harder extension adjustment at the same The level can either be too low or too high. Remember that too
suspensions according to the road conditions. time. much oil inside the fork will involve a more frequent air drain-
Always start from the standard calibration before making any Shock absorber: have a harder compression, and expecially a age. When the suspensions do not react to the changes of cali-
change on the suspensions. Afterwards, increase or decrease the harder extension adjustment. Work on the spring preload to bration, check that the adjusting units are not blocked.
adjusting clicks one at a time. lower the motorcycle rear side.

HARD GROUND MUDDY GROUND

Fork: softer compression adjustment. Fork: have a harder compression adjustment, or replace the
Shock absorber: softer compression adjustment. standard spring with a harder one.
The softer adjustment for the two suspensions is also used both Shock absorber: have a harder compression and extension ad-
in compression and in extension when driving at top speed, in justments, or replace the standard spring with a harder one.
order to have better grip of the tires. Work on the spring preload to lift the motorcycle rear side.
We advise replacing the springs of both suspensions to compen-
sate the weight increase due to the piling of the mud.

­28
The standard calibrations and the adjustment procedures are tighten the valve. - WR:
shown below. Remove the fork legs from the fork to check the oil level. Work
WARNING: Never force the adjusting screws as follows:
ADJUSTING THE COMPRESSION FORK beyond the maximum opening and closure - remove the damper rod caps;

EN
a) COMPRESSION (CR: UPPER REGISTER; WR: LOWER REGISTER) positions. - remove springs from the legs letting the oil drain into the
Standard calibration: -9 clicks (CR) legs;
Standard calibration: -10 clicks (WR) OIL FORK LEVEL - bring fork to stroke end;
For the regular fork operation, both legs must be provided with - check that level is at the distance (A) of 140 mm (5,51 in.)
Remove plug (B) and turn register (A) clockwise until the posi- from rod upper limit.
tion of fully closed is reached then, turn back by the mentioned the necessary oil quantity.
clicks.To obtain a smoother braking action, turn the register
anticlockwise. Reverse the operation in order to obtain a harder OIL QUANTITY IN EACH FORK LEG NOTE
action. - CR: 352 cm3 Always replace both the spring and the spacers to keep the
preload value unchanged.
b) EXTENSION (CR: LOWER REGISTER; WR: UPPER REGISTER)
Standard calibration: -13 clicks (CR)
Standard calibration: -10 clicks (WR) b) D WR
To reset standard calibration turn register (C) clockwise to reach C A
the position of fully closed; then, turn back by the mentioned
clicks. To obtain a smoother braking action, turn the register
anticlockwise. Reverse the operation in order to obtain a harder
action.
c) AIR VENT (to carry out after each competition, or monthly).
Set the motorcycle on a central stand and release the fork fully
and loosen the air vent valve (D). Once this operation is over,
WR
a) A a) b) C CR
A
D

WR CR
­29
HANDLEBAR POSITION AND HEIGHT CHANGE a) Handlebar position change b) Handlebar height change
Turn the lower clamp (2) 180° to move forward or backward Remove the lower spacer (A) then replace the screw (4) with a
The handlebar position (a) and height (b) can be changed for
(10mm- 0.04in.) the handlebar position with respect to the new one of L=65 mm (2.56 in.) height.
better suiting Your driving requirements. To effect these opera-
original setup. Once these operations are completed, tighten the screws (3) to
tions, remove the upper clamp (1) and the lower one (2), after
2,75-3,05 kgm (27-30 Nm; 19.9-22 Lb/fts) and the screws (4)
removing the fixing srews (3) and (4).
to 2,0-2,2 kgm (19,6-21,6 Nm; 14.5-15.9 Lb/fts

1
4 3

1 A
A

3
2

­30
ADJUSTING THE SHOCK ABSORBER 4. The difference between these two measurements constitutes ADJUSTING THE SHOCK ABSORBER SPRING
the “SAG” of the motorcycle’s rear end. PRELOAD
The rear shock absorber must be adjusted according to the rider Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with
weight and track conditions. Proceed as follows:
warmed up shock absorber.

EN
Proceed as follows: 1. First turn counterclockwise fastening rear pin (1) then re-
5. To get the right SAG according to your weight, adjust the move saddle, screws (2) and R.H. side panel (3).
1. With motorcycle on the stand, measure distance (A). shock absorber spring preload as described at side.
2. Take the normal riding position on the motorcycle with all
your riding apparel. WARNING*: Never disassemble shock ab-
3. With somebody’s help, take the new distance (A). sorber, which contains highly compressed
nitrogen. Contact your Dealer for such major
service. Do not incinerate.
B: axis of the panel screw
C: axis of rear wheel pin

2
A

­31
2. Clean ringnut (1) and adjusting nut (2) of the spring (3). SHOCK ABSORBER DAMPING ADJUSTMENT To reset the standard calibration, turn upper registers (4) and
3. Either with a hook wrench or an aluminium punch, loosen (6) clockwise until reaching fully closed position.
Adjustment of the compression stroke is independent from the
the ringnut . Return then back for the mentioned clicks. In order to obtain a
rebound stroke.
4. Turn the adjusting nut as required. smooth braking action, turn the registers anticlockwise. Reverse
5. When the adjusting operation is over (according to your A) COMPRESSION - Standard calibration: the operation in order to obtain a harder braking action.
weight and riding style), tighten the ringnut. (Torque for 1) Low damping speed:
both ringnuts: 5 Kgm; 49 Nm; 36.2 ft/lb). - 15 clicks (± 2 clicks) B) EXTENSION - Standard calibration:
6. Reassemble R.H. side panel and saddle. (register 4) - 18 clicks (± 2 clicks)

WARNING*:Be careful not to touch hot ex- 2) High damping speed: To reset the standard calibration, turn lower register (5) clock-
haust pipe while adjusting the shock abosr- - 15 clicks (± 2 clicks) wise until reaching fully closed position. Return then back for
ber. (register 6) the mentioned clicks. In order to obtain a smooth braking
action, turn the register anticlockwise. Reverse the operation
in order to obtain a harder braking action

5
3

­32
CHAIN ADJUSTMENT (Fig. A) Fast adjustment (Fig. B.)

Chain should be checked, adjusted and lubricated as per the Push the chain towards the final part of runner and check that
Maintenance Chart to ensure security and prevent excessive between the two elements a distance “A” from 0 to 2 mm is

EN
wear. If the chains becomes badly worn or is poorly adjusted present. If this is not the case, go on as follows:
(i.e., if it is too loose or too taught), it could escape from sprock- - Unloose the fastening nut of the wheel pin (1) on the right
et or break. side;
To adjust the rear chain it is necessary to lower the rear part of - Unloose the lock nuts (2) on both chain adjusters and turn the
motorcycle so to line up the drive sprocket axle, the rear swing screws (3) to obtain the correct tension value;
arm axle and the rear wheel axle as shown on drawing. Than - Tighten the lock nuts.
let turn three times the rear wheel. Now the chain should not After adjustment check that the wheel is lined up and tighten
be tight. its axle.

Fig. B

Fig. A 3

2
1
Drive sprocket axle

Rear swing arm axle Rear wheel axle

­33
CHECKING THE WEAR OF CHAIN, PINION AND Check the pinion damages or wear and replace it should the LUBRICATING THE CHAIN
SPROCKET wear degree be as the one shown in figure.
Proceed as follows: Remove the wheel and check the wear of the rear sproket teeth. Lubricate the chain following these instructions.
- fully stretch the chain with the adjusting screws. The below figure shows the outline of teeth in normal and exces-
- mark 20 chain links. sive wear. Should the sprocket be badly worn out, replace it by WARNING * : Never use grease to lubricate
- measure the distance “A” between 1st pin center and 21 st loosening the six fastening screws to the hub. the chain. Grease helps to accumulate dust
pin center. and mud, which act as abrasive and hepl to
rapidly wear out the chain, the sprocket, and
WARNING*: Misalignment of the wheel will the crown.
WEAR result in abnormal wear and may result in
STANDARD
LIMIT an unsafe riding condition.
317,5 mm 323 mm
(12,5 in) (12,72 in) Note*: In muddy and wet conditions, mud Disassembling and cleaning
sticks to the chain and sprockets resulting When particularly dirty, remove and clean the chain before
in an overtight chain. The pinion, the chain, lubrication.
and the rear sprocket wheel wear increases Work as follows:
when running on muddy ground. 1 - Set a stand or a block under the engine and see that the rear
wheel is lifted from the ground.
Remove: screws (1), transmission sprocket guard (2), clip
(3), master link (4) and transmission chain (5);
To reassemble, reverse the above procedure.

Normal consumption

Excessive consumption

­34
2 - Check that the chain is neither worn out nor damaged. If the 5 - If the chain has been cut, reassemble using a joint. WARNING: The chain oil has NEVER to get in
rollers or the links are damaged, replace the chain by fol- 6 - Assemble the joint spring (a) by turning the closed side to the contact with the tires or the rear brake disk.
lowing the instructions given in the Periodical Maintenance chain direction of rotation as shown in figure below.
Table. Chain tension rollers, chain driving roller,

EN
3 - Check that neither the sprocket nor the crown are damaged. chain guide, chain runner
4 - Wash and clean the chain as described hereunder. NOTE*: Even if all the joints are reusable when in good con- Check the wear of the above mentioned elements and replace
ditions, for safety purposes we advise using new joints when them when necessary.
Washing the chain without OR (CR) reassembling the chain.
Wash using either oil or diesel oil. When using gasoline or tri-
cloroetilene, clean and lubricate the chain to prevent oxidation. 7 - Accurately adjust the chain as described on page 33. WARNING*: Check the chain guide aligne-
ment, and remember that a bent element
Washing the chain with OR (WR) can cause a rapid wear of the chain. In this
Wash using oil, diesel oil, or paraffin oil. Never use gasoline, case, a chain fleeting from the sprocket may
tricloroetilene, or solvents, as the OR may suffer damages. ensue.
Use instead special sprays for chains with OR.

Lubricating the chain without OR (CR)

First dry, then plunge the chain in a bisulphide molybdenum
lubricant, or in high viscosity engine oil. Warm up the oil before 4
use.
Note * : As an alternative, you can use suitable spray lubri-
cants.

Lubricating the chain with OR (WR)

Lubricate all metallic and rubber (OR) elements using a brush,
and use engine oil with SAE 80-90 viscosity for the internal and
1
external parts.
Note * : As an alternative, you can use suitable spray lu- 2
bricants.

a
1- Chain tension roller 3
2- Chain driving roller
3- Chain guide
4- Chain slider
a- Joint spring

­35
Removing the front wheel NOTES
Do not operate the front brake lever when the wheel has been
Set a stand or a block under the engine and see that the front removed; this causes the caliper piston to move outwards. After
wheel is lifted from the ground. Loosen the bolts (1) holding removal, lay down the wheel with brake disc on top.
the wheel axle (2) to the front
fork stanchions.
Hold the head of the wheel axle (2) in place, unscrew the bolt
(3) on the opposite side; draw the wheel axle out.

1
1

2 3

­36
Reassembling the front wheel Fit the wheel axle (2) from the R.H. side, after greasing it and NOTE
push it to the stop on the L.H. leg; during this operation, the After reassembly, pump the brake control lever until the pads
Fit the L.H. spacer on the wheel hub. wheel should be turned. Tighten the screw (3) on the fork L.H. are against the brake disc.
Fit the wheel between the front fork legs so that the brake disc side but DO NOT lock it. Now, pump for a while, pushing the

EN
is fitted into the caliper. 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 (10,4 Nm/ 1,05 Kgm/
7.7 ft-lb).
Check that the brake disc slides between the caliper pads with-
out any friction.

1
3

­37
Removing the rear wheel NOTES
Do not operate the rear brake pedal when the wheel has been
Unscrew the nut (1) of the wheel pin (3) and extract it. It is
removed; this causes the caliper piston to move outwards.
not necessary to unloose the chain adjusters (2); in this way,
After removal, lay down the wheel with brake disc on top.
the chain tension will remain unchanged after the reassembly.
After reassembly, pump the brake control pedal until the pads
Extract the complete rear wheel, by taking care of the spacers
are against the brake disc.
located at the hub sides.
To reassemble, reverse the above procedure remembering to
insert the disc into the caliper.

1 2

­38
TIRES BRAKES 6. Rear brake oil tank
7. Rear brake hose
Care should be taken to keep the tires properly inflated. See tire The mayor components are brake master cylinder with its lever
8. Rear brake caliper
data for correct tire inflation pressure (page 8). Replace the tire (front) or pedal (rear), brakeline, caliper assembly and disc.
9. Rear brake disc

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if its wear exceeds what is shown on the table below.
10. Rear brake pump
LEGEND
11. Rear brake control pedal
MINIMUM HEIGHT OF 1. Front brake control lever
THE TREAD 2. Front brake pump with oil reservoir
3. Front brake hose
4. Front brake caliper
FRONT 3 mm (0.12 in) 5. Front brake disc
REAR 3 mm (0.12 in)

2 1 6
11
3

10

8 7
9

5 4

­39
BRAKE PADS REMOVAL PADS WEAR
Inspect pads for wear.
- Remove springs (1). Service limit “ A” is: 3,8 mm (0.15 in.).
- Remove pins (2). If service limit is exceeded, always replace the pads in pairs.
- Remove pads.

CAUTION!
Don’t operate the brake lever or pedal while
removing the pads.

FRONT

2
1

1 2 REAR FRONT REAR

­40
PADS CLEANING WARNING!
Do not attempt to ride the motorcycle until
Be careful that no disc brake fluid or any oil gets on brake pads
the brake lever or pedal are
or discs. Clean off any fluid or oil that inadverently gets on the
fully effective. Pump the brake

EN
pads or disc with alcohol.
lever or pedal until the pads are against the
Replace the pads with new ones if they cannot be cleaned sat-
discs.
isfactorily.
The brake will not function on the first ap-
PADS INSTALLATION plication of the lever or pedal.

- Install new brake pads.

- Reassemble the two pins (2) and the springs (1).

FRONT

2
1

1 2 REAR

­41
BRAKE DISC WEAR DISC WARPAGE
Measure disc warpage. Service limit for both discs is 0,15 mm
Measure the thickness of each disc at the point where it has
(0.006 in.)
worn the most. Replace the disc if it has worn past the service
Replace the disc if warpage is more than service limit.
limit.

Disc Thickness

SERVICE
DISC
STANDARD LIMIT

Front 3 mm 2,5 mm
(0.12 in) (0.10 in)

Rear 4 mm 3,5 mm
(0.16 in) (0.14 in)

­42
DISC CLEANING
Poor braking can also be caused by oil on the disc. Oil or grease
on the disc must be cleaned off with a high flash-point oil free

EN
solvent, such as acetone or lacquer thinner.

­43
ELECTRICAL COMPONENTS LOCATION - Voltage regulator (5) secured onto a bracket close to transdu- WR
cer. The electric system includes the following elements:
The ignition system includes the following elements:
- Flashing indicator device (7) under the fuel tank
- Generator (1), in oil bath, on the inner side of L.H. crankcase
- Headlamp (8) with two filaments bulb of 12V-35/35W and
cover; CR parking light bulb of 12V-5W;
- Spark plug (5) on the cylinder head.
- Back light (9) LED type;
CR
- Turn signals bulb (10) of 12V-10W;
- Electronic ignition coil (2) under the fuel tank;
- Electronic control unit (3) positioned on left-hand side, under
tank.
WR
- Transducer (4) secured onto a bracket under fuel tank; 3

WR 8

10

1 7

CR WR
9
2 5 10

4
6

­44
HEADLAMP BULBS REPLACEMENT (WR) - remove the two filaments bulb (7) connector (2) and the boot TAIL LIGHT (WR)
(3);
To gain access to the healamp bulbs, proceede as follows:
- remove the screw (6); The back light is a LED light.
- remove the upper fastening screw of the the headlamp carrier to
- release the bulb holding spring (4) and then the bulb itself.

EN
the instrument panuel support (A);
- push forward the headlamp carrier (B) and pull it towards the
To replace the parking light bulb (5) extract it from the inside
high (C) in order to uncouple from the two lower supports.
cover.
- remove the headlamp carrier;
After replacement, reverse operations for reassembly.

B
3
5 4 5
4

3
2 7
6

­45
REPLACING THE NUMBER PLATE LAMP (WR) ADJUSTMENT OF HEADLIGHT (WR) Adjust the preadlamp aiming by turning screw (1) to lower or
lift the high beam.
Pull out the number plate lampholder (4) from the back of the When checking the proper orienting of headlight, inflate tires
vehicle. Pull out the lampholder and the bulb. Rotate the bulb at right pressure, sat a person on the saddle and place the mo-
(5) to remove from the lampholder. torcycle perpendicular with its longitudinal axis 10 meter (33
ft) from a wall or screen. Then trace an horizontal line equal to
Once the bulb has been replaced, reverse the above procedure. the height of headlight center and a vertical one in line with its
longitudinal axis.

If possibile, execute this operation in a shadowy place.

When the low beam is on, the upper boundary limit between
dark and lit zone should be 9/10 th of headlight center from
groud.

4
1

­46
APPENDIX WARNING To put the motorcycle back into the use after storage.
Never litter the environment with fuel, and - Make sure the spark plug is tight.
AFTER-RACE CHECK POINTS
let the engine running in open air, never in - Fill the fuel tank.
After racing, first clean the motorcycle and then inspect the
closed rooms. - Run the engine for about 5 minutes to warm the oil then drain

EN
entire motorcycle, with special attention to the items listed in
the oil.
«MAINTENANCE» table (Appendix A), such as the air cleaner,
- Lubricate the drive chain and all the cables. - Put in fresh transmission oil (page 19).
carburetor, brakes, etc.
- Spray oil on all unpainted metal surfaces to prevent rusting. - Check all the points listed under the inspection and Adjustment
Carry out general lubrication, and make adjustment as neces-
Avoid getting oil on rubber parts or in the brakes. Section (Appendix A).
sary.
- Set the motorcycle on a box or stand so that both wheels are - Lubricate the points (listed in the Lubrication Section (Appendix
After every race, always check the correct tightening of all
raised off the ground. (If this cannot be done, put boards un- A).
screws and bolts.
der the front and rear wheels to keep dampness away from
STORAGE the tire rubber).
When the motorcycle is to be stored for any length of time, is - Tie a plastic bag over the exhaust pipe to prevent moisture
should be prepared for storage as follows: from entering.
- Clean the entire motorcycle thoroughly. - Put a cover over the motorcycle to keep dust and dirt from
- Empty the fuel from the fuel tank, and empty the carburetor collecting on it.
float bowl. (If left in for a long time, the fuel will deteriorate).

­47
CLEANING
IMPORTANT RECOMMENDATION

Premised that, before the motorcycle washing, it is necessary to

protect opportunely from the water the following parts:
a) Rear opening of the muffler;
b) Clutch and brake levers, hand grips, handlebar commuta-
tors;
c) Air cleaner intake;
d) Fork head, wheel bearings;
e) Rear suspension links.

­48
it is necessary ABSOLUTELY TO AVOID THAT After washing:
HIGH PRESSURE JETS OF WATER OR AIR come - Lubricate the points listed in the Maintenance Table (Appendix A).
to contact with THE ELECTRICAL PARTS, espe- - Start the engine and run it for 5 minutes.
cially the electronic control unit (1) and the - Test the brakes before riding the motorcycle.

EN
dashboard (2).
WARNING*: Never wax or lubricate the
brake disc. Loss of braking and an accident
could result. Clean the disc with an oilless
solvent such ans acetone. Observe the sol-
vent warnings.

CR WR

­49
Comando acceleratore Controllo funzionalità ❏ Serraggio viti e dadi Controllo / serraggio ❏
Comando acceleratore Verifica/regolazione gioco ❏ Fascette stringitubo Controllo / serraggio ❏
Comando starter Controllo funzionalità ❏ Lubrificazione generale ❏
Trasmissioni e com. fless. Controllo / Regolazione ❏ Collaudo generale ❏
Catena di trasmissione Controllo / Regolazione ❏

PRE -DELIVERY INSPECTION

Description Operation Pre-delivery Description Operation Pre-delivery

Engine oil Check level ❏ Tyres Check pressure ❏

Two-stroke mix oil level Check level ❏❆ Side stand Check operation ❏
Coolant Check / Restore level ❏ Side stand switch Check operation ❏
Cooling system Check for leakage ❏ Electrical equipment Check operation ❏
Electric fans Check operation ❏❆❆ Instrument panel Check operation ❏
Spark plugs Check / Replace ❏ Lights / Visual signals Check operation ❏
Throttle body / Carburettor Check and adjust ❏ Horn Check operation ❏
Brakes / Clutch fluid Check level ❏ Headlight Check operation ❏
Brakes / Clutch Check operation ❏ Ignition switch Check operation ❏
Brakes / Clutch Check lines for leakage ❏ Locks Check operation ❏
Throttle control Check operation ❏ Screws and nuts Check / Tighten ❏
Throttle control Check / Adjust play ❏ Hose clamps Check / Tighten ❏
Choke control Check operation ❏ General lubrication ❏
Flexible controls and transm. Check / Adjust ❏ General test ❏
Drive chain Check / Adjust ❏
❆ : presenti solo sui motocicli con motore a 2 tempi ❆ : only for motorcycles with 2 stroke engine
❆❆ : presente solo su alcuni modelli ❆❆ : only for some models

279

­50
ALPHABETIC INDEX Fuel cock.........................................................................................9 S
Page Shock absorber damping adjustment.............................................32
A G Sidestand........................................................................................9
Adjusting the compression fork......................................................29 Gear shift control..........................................................................15 Spark control ...............................................................................23
Adjusting the shock absorber.........................................................31 Steering lock (wr).........................................................................13

EN
Adjusting the shock absorber spring preload..................................31 H Steering wheel ball play adjustment..............................................25
Adjusting the suspensions according to particular track conditions...... Handlebar commutator (wr)..........................................................14 Stopping the motorcycle and the engine........................................18
..............................................................................................28 Handlebar position and height change..........................................30 Storage . ......................................................................................47
Adjustment of headlight (wr)........................................................46 Headlamp bulbs replacement (wr)................................................45
Adjustment of the control lever and check of the front brake fluid T
level ............................................................................................26 I Table for lubrication, supplies..........................................................8
After-race check points..................................................................47 Identification data...........................................................................5 Tail light (wr)................................................................................45
Air filter and cleaning...................................................................24 Idling adjustment..........................................................................21 Technical data.................................................................................7
Air filter check...............................................................................24 Important.......................................................................................3 Throttle cable adjustment..............................................................21
Assembly......................................................................................24 Important notices............................................................................2 Throttle control..............................................................................13
Tires.............................................................................................39
B Transmission oil change................................................................19
Brake disc wear.............................................................................42 K Transmission oil level checking......................................................19
Brake pads removal......................................................................40 Kickstart pedal..............................................................................15
Brakes..........................................................................................39 V
L Voltage regulator (wr)...................................................................23
C Lubricating the chain.....................................................................34
Carburetor choke .........................................................................10
Chain adjustment (fig. A)..............................................................33 O
Checking the fluid level.................................................................27 Oil fork level.................................................................................29
Checking the wear of chain, pinion and sprocket...........................34
Checks while running in................................................................16 P
Cleaning.......................................................................................48 Pads cleaning................................................................................41
Clutch adjustment.........................................................................22 Pads installation...........................................................................41
Clutch control................................................................................14 Pads wear . ..................................................................................40
Controls .........................................................................................9 Precautions for children..................................................................3
Control location...............................................................................6 Presentation....................................................................................2
Coolant level check........................................................................19
R
D Rear brake control........................................................................14
Digital instrument, warning lights (wr)..........................................11 Rear brake idle stroke adjustment.................................................27
Disc cleaning.................................................................................43 Rear brake pedal position adjustment ..........................................27
Reassembling the front wheel.......................................................37
E Removing the front wheel.............................................................36
Electrical components location.......................................................44 Removing the rear wheel..............................................................38
Engine start..................................................................................17 Replacement of cooling fluid.........................................................20
Engine stop button (cr)..................................................................14 Replacing the number plate lamp (wr)..........................................46
Riding...........................................................................................16
F Running in....................................................................................16
Front brake control.......................................................................13
Fuel..............................................................................................10

­51
APPENDICE A
APPENDIX A
APPENDICE A
ANHANG A
APÉNDICE A

­A1
­A2
 A
­A3
­A4
 A
­A5
­A6
 A
­A7
­A8
 A
­A9
­A10
 A
­A11
­A12
 A
­A13
LEGENDA- KEY FOR MAINTENANCE SCHEDULE- LEGENDE NOTE- NOTE- NOTE
h: ORE- HOURS- HEURES SOSTITUIRE LE GUARNIZIONI IN OCCASIONE DI OGNI SMON-
S: SOSTITUZIONE- REPLACEMENT- REMPLACEMENT TAGGIO- EVERY REMOVAL REPLACE ALL GASKETS- TOUTES
C: CONTROLLO- CHECK- CONTRÔLE LES DÉMONTAGES, REMPLACER LES GARNITURES
P: PULIZIA- CLEANING- NETTOYAGE
SOSTITUIRE LA VITERIA IN CASO DI DETERIORAMENTO- RE-
R: REVISIONE- OVERHAUL- REVISION PLACE SCREWS AND NUTS IF WORN- AU CAS DE DÉTÉRIO-
L: INGRASSAGGIO/ LUBRIFICAZIONE- GREASING/ LUBRICATION- LUBRIFICATION-GRAISSAGE RATION, REMPLACER LES BOULONS

(**): SOSTITUIRE L’OR INTERNO AD OGNI SMONTAGGIO DELLA TESTA- EVERY CYLINDER HEAD REMOVAL, REPLACE THE INNER O-RING- TOUTES LE DÉMONTAGE DE
LA CULASSE, REMPLACER LE GARNITURE O- RING INTÉRIEUR DOPO PERCORRENZE SU FANGO O SABBIA EFFETTUARE UNA
VERIFICA GENERALE- GENERAL CHECK AFTER RACING USE
ON MUDDY OR SANDY GROUNDS- APRÈS USAGE SUR DES
(*): RUOTARE DI 45° LE BUSSOLE DI FISSAGGIO- ROTATE 45° THE FASTENING BUSHES- TOURNER DE 45° LES DOUILLES DE FIXATION
TERREINS BOUEUX OU SABLEUX, EFFECTUER UN CONTRÔLE
GENERAL
MX: MOTOCROSS

EN: ENDURO

LEGENDE- LEYENDA ANMERKUNG- NOTAS

h: STUNDEN- HORAS DICHTUNGWECHSE: BEI JEDEM DEMONTAGE- SUBSTI-

TUIR LAS EMPACURAS EN EL CASO DE DESMONTAJE
S: WECHSELN- SUBSTITUCIÓN
SCHRAUBEN VERSCHLEISS: WECHSELN- SUBSTITUIR
C: KONTROLLIEREN- CONTROL TORNILLOS Y TUERCAS EN EL CASO DE DESGASTE

P: REINIGEN- LIMPIEZA SCHLAMMIGES UND SANDIGES GELÄNDEN: EIN ALLGE-

MEINE KONTROLLE DURCHFÜHREN- DESPUÉS DE LA
R: REVISION- REVISION CARRERA SOBRE UN TERRENO FANGOSO O ARENOSO,
EFECTUAR UN CONTROL GENERAL
L: SCHMIERUNG/BESCHMEIREN- ENGRESAJE/LUBRICACIÓN

(**): INNERE O- RING AUSWECHSELN: BEI JEDEM ZYLINDERKOPF DEMONTAGE- TOUTES LE DÉMONTAGE DE
LA CULASSE, REMPLACER LE GARNITURE O- RING INTÉRIEUR

(*): ROTIEREN 45° BEFESTIGUNGBUCHSEN- GIRAR DE 45° LOS MANGUITOS DE FIJACIÓN

MX: MOTOCROSS

EN: ENDURO

­A14
 A
­A15
­A16
 A
­A17
­A18
 A
­A19
­A20
 A
­A21
­A22
 A
­A23
­A24
 A
­A25
­A26
 A
­A27
LEGENDA- KEY FOR MAINTENANCE SCHEDULE- LEGENDE NOTE- NOTE- NOTE
h: ORE- HOURS- HEURES SOSTITUIRE LE GUARNIZIONI IN OCCASIONE DI OGNI SMON-
S: SOSTITUZIONE- REPLACEMENT- REMPLACEMENT TAGGIO- EVERY REMOVAL REPLACE ALL GASKETS- TOUTES
C: CONTROLLO- CHECK- CONTRÔLE LES DÉMONTAGES, REMPLACER LES GARNITURES
P: PULIZIA- CLEANING- NETTOYAGE
SOSTITUIRE LA VITERIA IN CASO DI DETERIORAMENTO- RE-
R: REVISIONE- OVERHAUL- REVISION PLACE SCREWS AND NUTS IF WORN- AU CAS DE DÉTÉRIO-
L: INGRASSAGGIO/ LUBRIFICAZIONE- GREASING/ LUBRICATION- LUBRIFICATION-GRAISSAGE RATION, REMPLACER LES BOULONS

(**): SOSTITUIRE L’OR INTERNO AD OGNI SMONTAGGIO DELLA TESTA- EVERY CYLINDER HEAD REMOVAL, REPLACE THE INNER O-RING- TOUTES LE DÉMONTAGE DE
LA CULASSE, REMPLACER LE GARNITURE O- RING INTÉRIEUR DOPO PERCORRENZE SU FANGO O SABBIA EFFETTUARE UNA
VERIFICA GENERALE- GENERAL CHECK AFTER RACING USE
ON MUDDY OR SANDY GROUNDS- APRÈS USAGE SUR DES
(*): RUOTARE DI 45° LE BUSSOLE DI FISSAGGIO- ROTATE 45° THE FASTENING BUSHES- TOURNER DE 45° LES DOUILLES DE FIXATION
TERREINS BOUEUX OU SABLEUX, EFFECTUER UN CONTRÔLE
GENERAL
MX: MOTOCROSS

EN: ENDURO

LEGENDE- LEYENDA ANMERKUNG- NOTAS

h: STUNDEN- HORAS DICHTUNGWECHSE: BEI JEDEM DEMONTAGE- SUBSTI-

TUIR LAS EMPACURAS EN EL CASO DE DESMONTAJE
S: WECHSELN- SUBSTITUCIÓN
SCHRAUBEN VERSCHLEISS: WECHSELN- SUBSTITUIR
C: KONTROLLIEREN- CONTROL TORNILLOS Y TUERCAS EN EL CASO DE DESGASTE

P: REINIGEN- LIMPIEZA SCHLAMMIGES UND SANDIGES GELÄNDEN: EIN ALLGE-

MEINE KONTROLLE DURCHFÜHREN- DESPUÉS DE LA
R: REVISION- REVISION CARRERA SOBRE UN TERRENO FANGOSO O ARENOSO,
EFECTUAR UN CONTROL GENERAL
L: SCHMIERUNG/BESCHMEIREN- ENGRESAJE/LUBRICACIÓN

(**): INNERE O- RING AUSWECHSELN: BEI JEDEM ZYLINDERKOPF DEMONTAGE- TOUTES LE DÉMONTAGE DE
LA CULASSE, REMPLACER LE GARNITURE O- RING INTÉRIEUR

(*): ROTIEREN 45° BEFESTIGUNGBUCHSEN- GIRAR DE 45° LOS MANGUITOS DE FIJACIÓN

MX: MOTOCROSS

EN: ENDURO

­A28
MEMORANDUM

A
­A29
 MEMORANDUM

­A30