Husqvarna CR 125 2011 Workshop Manual
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Husqvarna CR 125 2011 Workshop Manual

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CR 125 2011
WR 125 2011
Workshop Manual
Ed. 06-2011

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Summary of Contents for Husqvarna CR 125 2011

  • Page 1 CR 125 2011 WR 125 2011 Workshop Manual Ed. 06-2011...
  • Page 2 HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for 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.

  • Page 3: Foreword, Table Of Contents

    FOREWORD, TABLE OF CONTENTS CR 125 2011 - WR 125 2011 Workshop Manual TE 250 - 310 2011 I.E. CR 125 2011 WR 125 2011 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel.
  • Page 4 CR 125 2011 - WR 125 2011 Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple- ment to operator training and operators should become thoroughly familiar with it.

  • Page 5: Table Of Contents

    FOREWORD, TABLE OF CONTENTS CR 125 2011 - WR 125 2011 Table of Contents Title Section Foreword, Table of contents ................a Important notices ....................b General information .....................A Maintenance ......................B Troubleshooting ....................C Settings and adjustments ................... D General procedures .....................E Engine disassembly.....................F...

  • Page 7: Important Notices

    IMPORTANT NOTICES CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 8 IMPORTANT NOTICES CR 125 2011 - WR 125 2011 CR models are RACING motorcycles and are warranted to be free from op- CR 125 erating defects; a scheduled maintenance chart for racing use is provided in Section B. WR models are for ROAD USE (DERATED); they are guaranteed exempt from...

  • Page 9: General Information

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 10 GENERAL INFORMATION CR 125 2011 - WR 125 2011 Engine ......................A.3 Starting ......................A.3 Timing system ....................A.3 Lubrication ....................A.3 Ignition ......................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...

  • Page 11: Starting

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 Engine Type ................single cylinder, 2 stroke Cooling ...................... liquid Bore ..................mm 54 (2.12 in.) Stroke ................... mm 54,5 (2.14 in.) Displacement .............. cm 124,82 (7.61 cu. in.) Compression ratio (with closed ports) ............8,8:1 Starting Type.....................

  • Page 12: Transmission Ratio

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 Transmission ratio 1st gear..................2,357 (z 33/14) 2nd gear ..................1,866 (z 28/15) 3rd gear ..................1,579 (Z 30/19) 4th gear..................1,350 (Z 24/22) 5 th gear..................1,181 (Z 26/22) 6 th gear ..................

  • Page 13: Cold Tire Pressure

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 Cold tire pressure (front) (*) ..................12.8÷14.2 psi ( front) (%) ..................... 15.6 psi (rear) (*) ..................11.4÷12.8 psi (rear) (%) ....................14.2 psi (*) Racing use - (%) Road use...

  • Page 14: Overall Dimensions

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 CR 125 H06666 Overall dimensions Wheelbase A (CR) ................... mm 1460 (57.48 in.) (WR) .................. mm 1465 (57.68 in.) Overall length B (CR) ..................mm 2215 (87.2 in.) (WR) .................. mm 2260 (88.98 in.) Overall width C (CR) ..................

  • Page 15: Capacities

    GENERAL INFORMATION CR 125 2011 - WR 125 2011 WR 125 H06667 Capacities Type Quantity Fuel tank capacity (reserve included) 98 octane unleaded fuel 7 l -1.54 Imp. Gall 1.59 U.S. Gall Fuel reserve 1,5 l - 0.33 Imp. Gall 0.34 U.S.

  • Page 17: Maintenance

    MAINTENANCE CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 18 MAINTENANCE CR 125 2011 - WR 125 2011 WR - CR 125 SCHEDULED MAINTENANCE CHART Competition motorcycle, racing use: with full power engine ENGINE REPLACE IF NEC- COUPON COUPON COUPON COUPON COUPON ESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY...
  • Page 19 MAINTENANCE CR 125 2011 - WR 125 2011 WR - CR 125 SCHEDULED MAINTENANCE CHART Competition motorcycle, racing use: with full power engine CHASSIS REPLACE IF COUPON COUPON COUPON COUPON COUPON NECESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY EVERY...
  • Page 20 MAINTENANCE CR 125 2011 - WR 125 2011 WR - CR 125 SCHEDULED MAINTENANCE CHART Competition motorcycle, racing use: with full power engine CHASSIS REPLACE IF COUPON COUPON COUPON COUPON COUPON NECESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY EVERY...
  • Page 21 MAINTENANCE CR 125 2011 - WR 125 2011 WR 125 SCHEDULED MAINTENANCE CHART Standard motorcycle, street legal (with limited power engine) ENGINE COUPON COUPON COUPON COUPON COUPON REPLACE IF NECESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY 1000Km 1500 Km...
  • Page 22 MAINTENANCE CR 125 2011 - WR 125 2011 WR 125 SCHEDULED MAINTENANCE CHART Standard motorcycle, street legal (with limited power engine) CHASSIS COUPON COUPON COUPON COUPON COUPON REPLACE IF NECESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY 1000Km 1500 Km...
  • Page 23 MAINTENANCE CR 125 2011 - WR 125 2011 WR 125 SCHEDULED MAINTENANCE CHART Standard motorcycle, street legal (with limited power engine) CHASSIS COUPON COUPON COUPON COUPON COUPON REPLACE IF NECESSARY ITEM AFTER FIRST EVERY EVERY EVERY EVERY 1000Km 1500 Km...

  • Page 25: Troubleshooting

    TROUBLESHOOTING CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 26 TROUBLESHOOTING CR 125 2011 - WR 125 2011 ENGINE Trouble Cause Remedy Engine does not start or has starting trou- Insufficient compression bles 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston ring Replace 4.
  • Page 27 TROUBLESHOOTING CR 125 2011 - WR 125 2011 Trouble Cause Remedy Engine is noisy Noise seems to come from piston 1. Too much piston-to-cylinder clearance Replace 2. Worn piston rings or piston grooves Replace 3. Too much carbon build-up in combustion chamber...
  • Page 28 TROUBLESHOOTING CR 125 2011 - WR 125 2011 Trouble Cause Remedy Transmission jumps out of gear 1. Worn sliding gear dogs Replace 2. Worn gear grooves Replace 3. Worn dog slots in gears Replace 4. Worn selector shaft splines Replace 5.
  • Page 29 TROUBLESHOOTING CR 125 2011 - WR 125 2011 CHASSIS Trouble Cause Remedy The handlebar is hard to turn 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut Adjust overtightened 3. Bent steering stem Replace bottom yoke 4.
  • Page 30 TROUBLESHOOTING CR 125 2011 - WR 125 2011 Trouble Cause Remedy Rear suspension is noisy 1. Worn link rod spacers or bearings Replace 2. Worn shock absorber ball joints Replace 3. Shock absorber faulty Replace Poor braking 1. Air in brake system...

  • Page 31: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 32 SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Saddle removal.....................D.4 Tank removal ....................D.4 Throttle cable adjustment ................D.6 Idle adjustment .....................D.6 Clutch plate replacement ................D.7 Adjustment of the clutch control lever ............D.8 Front brake fluid level check ................D.9 Front brake lever adjustment ...............D.9 Rear brake pedal position adjustment ............D.10...
  • Page 33 SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 CR 125 H06664 WR 125 H06665 Workshop Manual Ed. 06-2011...

  • Page 34: Saddle Removal

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Saddle removal Turn the rear fixing (1) counter clockwise, remove it and extract the saddle. H06668 Tank removal Remove the saddle as described in the relevant paragraph. Remove the screws (1) and the side panels.
  • Page 35 SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Lift the front part of the tank (7) and remove it from the bike with the scoops. H06672 Workshop Manual Ed. 06-2011...

  • Page 36: Throttle Cable Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Throttle cable adjustment The throttle cable can be adjusted using the screw set on the throttle, or using the adjusting screw set on the carburettor cover. To check for proper adjustment of throttle cable, proceed as follows: remove rubber cap;...

  • Page 37: Clutch Plate Replacement

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Clutch plate replacement Drain transmission oil as outlined in the relevant paragraph. Remove the brake pedal (1). Remove the five retaining screws (2) and the clutch cover (3). Using an 8 mm wrench, unscrew the five screws (4) securing the clutch springs.

  • Page 38: Adjustment Of The Clutch Control Lever

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Adjustment of the clutch control lever To adjust the clutch control lever, you will need to adjust cable tension using the adjuster on the lever. Shift the rubber protection (1).

  • Page 39: Front Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Front brake fluid level check The level of the fluid in pump reservoir must never be below the minimum value (1), which can be checked from the window on the rear side of the pump body.

  • Page 40: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Rear brake pedal position adjustment The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs. For adjusting, proceed as follows: Loosen the screw (1).

  • Page 41: Rear Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Rear brake fluid level check Master cylinder fluid level - visible through sight glass (1) - must be above the minimum notch on master cylinder reservoir. A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.

  • Page 42: Changing Transmission/Gearbox Oil

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Changing transmission/gearbox oil 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. H06693 To change oil, unscrew the undersump cap (5), remove the cap (6) and let the oil drain completely;...

  • Page 43: Coolant Level Check

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 0.39 in. above the cells.

  • Page 44: Coolant Replacement

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Coolant replacement Place the vehicle on a flat ground and in horizontal position. Place a vessel of adequate capacity on the right side of the vehicle under the water pump (1).
  • Page 45 SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Pour the necessary quantity of coolant 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.

  • Page 46: Air Filter Check

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Air filter check Turn the rear fixing (1) counter clockwise, remove it and extract the saddle re- leasing it from the front retaining screw. Remove the screw (3), remove the complete air filter (4) and separate filter (5) from rear chassis (6).

  • Page 47: Assembly

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Assembly To ensure tight fit, slightly (C) grease filter edge on side facing filter housing. While re-inserting the filter into its housing, make surs that piece (A) is turned up- wards and edge (B) is on the left lower side of the filter case.

  • Page 48: Secondary Drive Chain Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Secondary drive chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart" (see Section B) to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taut), it could escape from sprocket or break.

  • Page 49: Chain Lubrication

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Chain lubrication Lubricate the chain following these instructions. Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets.
  • Page 50 SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 The chain lubricant shall NEVER get in contact 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.

  • Page 51: Suspension Setup According To Track Condition

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Suspension setup according to track condition Following are a few guidelines to find the right suspension setup for different types of terrain. Always start from the suspensions standard set- ting before making any change. Afterwards, increase or decrease the adjusting clicks, one at a time.

  • Page 52: Shock Absorber Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain condi- tions. Proceed as follows: 1. Place the motorcycle on the stand and measure distance (A).

  • Page 53: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Shock absorber spring preload adjustment Proceed as follows: 1. Place yourself on the right-hand side of the motorcycle. 2. Clean lock ring nut (1) and adjuster ring nut (2) of the spring (3).

  • Page 54: Shock Absorber Compression And Rebound Damping Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Shock absorber compression and rebound damping adjustment Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard setting: 1) Low damping speed: -15 clicks (± 2 clicks)

  • Page 55: Kayaba Front Fork Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 KAYABA front fork adjustment COMPRESSION (Fig. a) (CR: TOP ADJUSTER; WR: LOWER ADJUSTER) CR: -9 clicks WR: -10 clicks To reset standard calibration, turn adjuster screw (A) clockwise to reach the fully closed position;...

  • Page 56: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground.

  • Page 57: Changing Handlebar Position And Height

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Changing handlebar position and height Handlebar position (a) and height (b) can be modified to better suit your personal preferences. To perform these adjustments, remove the handlebar clamp bolts (3) and (4), and then remove the handlebar upper (1) and lower (2) clamps.

  • Page 58: Fuel Supply Hose Inspection

    SETTINGS AND ADJUSTMENTS CR 125 2011 - WR 125 2011 Fuel supply hose inspection Check the pipe (1) starting from tank cock and reaching the carburettor. If cracked, replace it by releasing the two clamps (2). Check the conditions of the breather hoses (3), if they are cracked or hard- ened they must be replaced.

  • Page 59: Exhaust Valve Position Check

    Exhaust valve position check H02846 H02848 The cylinder has a double exhaust valve system called H.T.S. (HUSQVARNA TORQUE SYSTEM), ensuring engine top performance. These valves are con- trolled by a centrifugal governor making them open at approx. 7500 rpm ± 200.

  • Page 61: General Procedures

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 62 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Foreword ......................E.3 Engine guard removal ..................E.4 Saddle removal.....................E.4 Side panels removal ..................E.5 Electronic control unit removal (CR) .............E.5 Removal of rear chassis complete with mudguard and air box ....E.6 Exhaust system removal ................E.9 Fuel tank and scoop removal ..............

  • Page 63: Foreword

    GENERAL PROCEDURES CR 125 2011 - WR 125 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.

  • Page 64: Engine Guard Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 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. H06693 Saddle removal - Turn the rear fixing (1) counter clockwise and remove the saddle.

  • Page 65: Side Panels Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 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). H06728 H06729 Electronic control unit removal (CR) Release connector (1) from control unit (2).

  • Page 66: Removal Of Rear Chassis Complete With Mudguard And Air Box

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Removal of rear chassis complete with mudguard 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).
  • Page 67 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 - Lift chassis (4) complete with filter box (5). H06735 Using an 8 mm wrench, loosen the two inside screws (6) and the two side screws (7) and remove the filter box (8). H06736 H06737 Workshop Manual Ed. 06-2011...
  • Page 68 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Using an 8 mm wrench, loosen the two screws (9), and remove shock ab- sorber protection (10). H06791 Remove rivets (13), and remove upper rubber protection (12). - Remove the air filter. H02754 Workshop Manual Ed. 06-2011...

  • Page 69: Exhaust System Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Exhaust system removal KEY: 1) Silencer 2) Rubber master link 3) Exhaust manifold 4) Springs H06994 Remove the saddle as described in the relevant paragraph. Remove the right-hand side panel as described in the relevant paragraph.
  • Page 70 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Remove clamp (3) and disconnect secondary air circuit pipe (4) from exhaust manifold (5). H06995 Release the two springs (6). H06751 To remove manifold (5), loosen screw (7) with an 8 mm wrench.

  • Page 71: Fuel Tank And Scoop Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Fuel tank and scoop removal H06741 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: Scoop Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Close fuel cock (3), release clamp (5), and disconnect pipe (4). H06743 Raise the tank (6) from the front end, and remove it from bike complete with scoops (7). H06744 Scoop removal Remove the saddle and side panels, as outlined in the relevant para- graphs.

  • Page 73: Spoiler Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Spoiler removal Remove the fuel tank as outlined in the relevant paragraph. Using an 8 mm socket wrench, loosen the two screws (11) and remove the left-hand side (12) and right-hand side (13) spoiler.

  • Page 74: Coil Removal (Cr)

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Coil removal (CR) Remove: saddle and fuel tank as described in the relevant paragraphs. Remove the spark plug cap (1). H06749 Using an 8 mm wrench, loosen the retaining screws (2) and remove the coil (3).

  • Page 75: Number Plate Holder Removal (Wr)

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Number plate holder removal (WR) Remove tail light as outlined in section M. Disconnect rear turning indicator connectors (1) and (2). H02744 Slide turning indicator cables out of rubber gaiter (3).

  • Page 76: Carburettor Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Carburettor removal Close fuel cock (1), release clamp (3), and disconnect pipe (2). H06756 Loosen clamps (6). H06997 Cut the clamps (5) and disengage the breather hoses (6) from their holder clamps.
  • Page 77 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Slightly turn carburettor (7) to the left, loosen the screws (8) and remove the cover (9). H06760 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: Chain Slider Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Chain slider removal Remove the chain as described in the relevant paragraph. Remove the circlip (1) and slide the sprocket (2) out. H06762 Loosen the four screws (3) on the slider (4) using an 8 mm wrench.

  • Page 79: Secondary Drive Chain Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 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). H06708 H06767 Chain guard removal (WR) Loosen screws (1) using an 8 mm wrench and remove the chain guard (2).

  • Page 80: Engine Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Engine removal Remove the saddle as described in the relevant paragraph. Remove the fuel tank as described in the relevant paragraph. Remove the exhaust system as described in the relevant paragraph.
  • Page 81 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Take off the spark plug cap (7). H06771 Disconnect the connector (8) of the power generator. H06772 Open clamps (9) and disconnect the hoses (10) that connect the cooling system to the engine.
  • Page 82 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Lift retaining tab, and disconnect clutch cable (11). H06779 Using a 12 mm wrench, loosen the screws (12) of the left-hand side bracket (13) of the head clevis and remove it.

  • Page 83: Radiator Removal

    GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Using a 27 mm wrench, loosen nut (19) on swinging arm shaft then, work- ing on the right side, remove swinging arm shaft until releasing engine, but without removing swinging arm.
  • Page 84 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Open clamps (5), and disconnect hoses (6) from right-hand radiator (7). H06783 Open clamps (8), and disconnect hoses (9) from left-hand radiator (10). Open clamp (11), and disconnect the radiator connecting hose (12).
  • Page 85 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Using an 8 mm wrench, loosen screws (13), and remove left-hand radiator (10). H07003 H06786 Workshop Manual Ed. 06-2011 E.25...
  • Page 86 GENERAL PROCEDURES CR 125 2011 - WR 125 2011 Using an 8 mm wrench, loosen screws (14), and remove right-hand radiator (7). H06788 H06789 Workshop Manual Ed. 06-2011 E.26...

  • Page 87: Thermostat Removal (Wr)

    GENERAL PROCEDURES CR 125 2011 - WR 125 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 89: Engine Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 90 ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Right-hand side component and cover disassembly ........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 ..........

  • Page 91: Right-Hand Side Component And Cover Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Right-hand side component and cover disassembly 14 13 20 17 H06792 To make disassembly operations easier, it is recommended to place engine block onto a rotating support, securing it on the upper side.

  • Page 92: Clutch Components

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Clutch components H07069 Screw Washer Spring Pressure plate Clutch assembly Thrust washer Needle roller bearing Retainer Ball 10 Pushrod Clutch control shaft 12 Lock washer 13 Nut 14 Clutch hub 15 Washer...

  • Page 93: Clutch-Side Crankcase Half Component Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Clutch-side crankcase half component disassembly Working crossways, loosen the five retaining screws (1) on clutch springs, and remove them together with the relevant washers (2) and springs (3). H06793 Remove pressure plate (4) and clutch plates pack (5) from hub.
  • Page 94 ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Carry out this 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.
  • Page 95 ENGINE DISASSEMBLY CR 125 2011 - WR 125 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). H06798 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 ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Slide water pump control gear (22) and primary drive gear (23) out of crank- shaft. Remove the Woodruff key from crankshaft. H06800 Slide selector shaft (26) out of right crankcase half rear side.

  • Page 97: Sprocket-Side Component And Cover Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Disengage return spring (27) on starter shaft (28) from its retainer on right crankcase half. H06539 Working on the inner side, slide out starter shaft assembly (28) complete with control gear, and collect washer (29).
  • Page 98 ENGINE DISASSEMBLY CR 125 2011 - WR 125 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 ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Prevent rotor rotation using a suitable tool. Using a 17 mm (CR) or 19 mm (WR) socket wrench, loosen rotor sealing nut. Remove lock washer. H06810 Use the tool (7) part no. 8000 60516 (WR) or 8000 46613 (CR) and secure it onto rotor.

  • Page 100: Intake Valve Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Loosen the screws (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.

  • Page 101: Exhaust Valve Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Remove intake valve (2) from crankcase, and collect gasket (3). H06548 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).

  • Page 102: Piston-Cylinder-And-Head Assy Disassembly

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Piston-cylinder-and-head assy disassembly Head, cylinder and piston can be disassembled also at an earlier stage, as this procedure is independent 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.
  • Page 103 ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Slide cylinder (6) out of crankcase stud bolts, by duly supporting piston with your hands when it is separated from cylinder. WARNING - When removing the cylinder, do not let it rotate as piston ring end could enter gaps thus preventing piston removal and causing damage to the piston ring itself.

  • Page 104: Splitting The Crankcase

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Splitting the crankcase Loosen the 12 retaining screws on left crankcase half. H06624 With the gearbox in neutral position, fit tool part no. 8000 79016 on left crank- case half (with 3 duly-sized "A" screws), work on the central pin and separate crankcase halves.

  • Page 105: Crankshaft Removal

    ENGINE DISASSEMBLY CR 125 2011 - WR 125 2011 Using pliers, counteract spring action and turn ratchet to allow selector shaft removal. Slide out selector shaft from the left side. H06556 Crankshaft removal Should it be necessary to remove crankshaft from right crankcase half, use the same tool part no.

  • Page 107: Engine Overhaul

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 108 ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Cleaning parts ..................... G.3 Compression ratio check ................G.4 Cylinder ....................... G.5 Cylinder measuring..................G.5 Clearances ....................G.6 Piston......................G.6 Piston groove height ..................G.6 Cylinder to piston clearance ................ G.7 Piston pin .....................

  • Page 109: Cleaning Parts

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Cleaning parts 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: Compression Ratio Check

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Compression ratio check To check if the compression ratio is correct, proceed as follows: a) remove the cylinder together with the head from the crankcase ; b) remove the piston from the connecting rod, carefully clean it and install it in-...

  • Page 111: Cylinder

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Cylinder Light alloy cylinder with "NIKASIL"-coated liner. Once the cylinder has been activated, the max. allowed 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.

  • Page 112: Clearances

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 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; whereas a loose fit will cause annoying vibration resulting in early wear of moving parts.

  • Page 113: Cylinder To Piston Clearance

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Cylinder to piston clearance The piston-cylinder units are supplied already coupled; should the cylinders and pistons of some units have been accidentally mixed up, it will be necessary to measure the diameters as outlined in the previous paragraphs.

  • Page 114: Piston Rings

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Piston rings Visually check the piston ring and the relevant seat in the piston. If the piston ring is worn or damaged, it has to be replaced (the set is available as spare part).

  • Page 115: Piston Pin-Piston-Connecting Rod Small End Clearance

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Piston pin-piston-connecting rod small end clearance The table below is a list of the possible clearances allowing to reach the right radial clearance of 0.002÷0.010 mm (0.000078÷0.000393 in.). If, during engine overhaul, a radial clearance higher than the max. allowed value of 0.015 (0.00059 in.) is found and the colour mark (C) is no longer vis-...

  • Page 116: Pin-Flywheel-Connecting Rod Big End Clearance

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Pin-flywheel-connecting rod big end clearance The table below is a list of the possible clearances allowing to reach the right radial clearance of 0.20÷0.028 mm. If, during engine overhaul, a radial clear- ance higher than the max.

  • Page 117: Connecting Rod

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Connecting rod Due to the stresses the connecting rod is subject to, its original dimensions change in a more or less noticeable way. The connecting rod tests are meant to check its wholeness.

  • Page 118: Head

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Head Remove carbon deposits from the combustion chamber. Make sure that there is no cracking and that the sealing surfaces do not feature scoring, dents or any other kind of damages. Flatness must be perfect as well as spark plug seat threading.

  • Page 119: Various Crankshaft Straightness Check

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Various crankshaft straightness check Place the crankshaft between centres and take the measurement with a dial gauge, checking that the detected value does not exceed 0.05 mm (0.00196 in.). H06578 Bearings Carefully wash bearings with mixture and dry with compressed air without turn- ing them.

  • Page 120: Needle Roller Bearing Replacement

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Needle roller bearing replacement To remove the needle roller bearing of the water pump shaft, use special tool part no. 8000 43824. H06581 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.

  • Page 121: Clutch Unit

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Clutch unit Inspect all clutch 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.

  • Page 122: Friction Plate To Clutch Housing Clearance

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Friction plate to clutch housing clearance Standard Max. size limit 0,15÷0,25 mm 0,35 mm (0.006÷0.010 in.) (0.014 in.) H06585 Clutch plate distortion Standard Max. wear limit 0.2 mm (within 0.05 mm) Friction plate (0.0078 in.)

  • Page 123: Gear Change

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Gear 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.

  • Page 124: Shifter Forks

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Shifter forks Visually inspect the shifter forks and replace any bent fork. A bent fork will make gears hard to engage and let the transmission jump out of gear unex- pectedly under loading.

  • Page 125: Control Shaft Groove Width

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Control shaft groove width Standard Max. size limit 6.05÷6.15 mm 6.20 mm (0.238÷0.242 in.) (0.244 in.) H06592 Carburettor overhaul, adjustment and maintenance The carburettor setting was determined by the manufacturer after performing extensive tests in a diverse range of condition of use;...

  • Page 126: Carburettor

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Carburettor H06882 The figure shows the carburettor parts. Some of them, which regulate the air and fuel flows, 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.

  • Page 127: Taper Needle Retainer Position

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 The diagram shows the influence of parts 1, 2, 3, 4, 5 on the throttle valve openings. A: idle air screw + idle jet B: taper needle groove C: taper needle...

  • Page 128: Taper Needle

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Taper needle The taper needle influences the air-fuel mixture from the small and medium openings of the throttle valve. Size 60, at the end of the code found on the part, indicates that the external diameter is 2.60 mm.

  • Page 129: How To Set The Carburettor

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 How to set the carburettor The paragraphs below explain how to modify the carburettor setting. Before making any changes, operate the motorcycle and observe the reactions of the engine to different openings of the throttle control, accelerations, etc..

  • Page 130: Throttle Valve Replacement

    ENGINE OVERHAUL CR 125 2011 - WR 125 2011 Throttle valve replacement The throttle valve’s bevelled edge height is printed on its top; when replacing the valve, switch to a larger or smaller one (if you want to impoverish or enrich the mixture) going up in size 0.5 each time.

  • Page 131: Engine Assembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 132 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 General ......................H.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: General

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 General To reassemble, reverse the disassembly procedure. Any special instructions concerning reassembly operations are expressly high- lighted in the text. Gaskets, oil seals, metal clips, sealing washers in deformable material (copper, aluminium, fibre etc.) and self- locking nuts must always be replaced.
  • Page 134 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Generic fasteners 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...

  • Page 135: Item Summary And General Assembly Notes

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Item summary and general assembly notes PARTS PROCEDURES Flywheel - Crankshaft taper end Degrease with suitable degreasers Crankcase crankshaft Fit the shaft inside the pre-heated bearings Starter drive shaft Press with "Loctite 648"...

  • Page 136: Gear Shift Part Reassembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Gear shift part reassembly Fit the original shim at the end of the output shaft. If the selector shaft or the gear shafts are replaced, it will be necessary to determine the thickness of the shims to be fitted in order to achieve the correct axial clearance.
  • Page 137 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Fit the selector shaft with its bearing and sector gear well lubricated with engine oil in the right half crankcase. If the ratchet is already assembled on the outer side of the crankcase half, use pliers to counteract the action of the spring so as to allow the insertion of the selector shaft.
  • Page 138 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 WARNING - In case of incorrect sealing, the following operating failures may occur: Air seepage causing a leaner mixture and possible engine seizure. Oil leak from gearbox area to crankshaft area; this may lead to a fast consumption of lubricant causing gearbox overheating and seizure.
  • Page 139 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Fit the original shim (4) on starter shaft end, and insert it in the right crankcase half seat. Mind the positioning of the clutch spring end, it must be fitted between the rear end of the crankcase half and the protruding tooth (D).

  • Page 140: Piston-Cylinder-And-Head Reassembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Fit the spacer (9) and the tab in the crankshaft seat, and install the primary drive gear (7) and the water pump control gear (8). H06968 Piston-cylinder-and-head reassembly Fit the roller cage on connecting rod small end, and position cylinder bottom seal (1).
  • Page 141 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Rotate the crankshaft and check that the piston (1) 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.
  • Page 142 ENGINE ASSEMBLY CR 125 2011 - WR 125 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. H06969 Workshop Manual Ed. 06-2011...

  • Page 143: Clutch Reassembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Clutch reassembly 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.
  • Page 144 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Install the lock washer and hub locking nut. While locking the hub with tool part no. 8000 79015, lock the nut with a 22 mm socket wrench to the specified tightening torque. Rivet washer onto nut.

  • Page 145: Right Cover Reassembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Fit the bearing thrust washer (7) and assemble the pressure plate (8). H06972 Fit the clutch springs (9) and lock them onto hub with the suitable washers and screws. H06973 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 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Fit these parts with the centrifugal governor (B) into their seats on the right- hand side cover. Fit the layshaft (C) with its control lever (D) and connection lever (E) into the right-hand side cover.
  • Page 147 ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Install the gasket on the crankcase half, and check the correct position of the centring bushings; proceed to RH cover reassembly, taking care that the water pump control shaft end can be easily installed inside its special cover seat.

  • Page 148: Exhaust Valve Reassembly

    ENGINE ASSEMBLY CR 125 2011 - WR 125 2011 Exhaust valve reassembly To reassemble the exhaust valves, simply reverse the removal procedure minding that with completely closed valves, the min. distance from the piston must be equal to or grater than 0.4÷0.5 mm (0.0157÷0.0197 in.).

  • Page 149: Front Suspension

    FRONT SUSPENSION CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 150 FRONT SUSPENSION CR 125 2011 - WR 125 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 Workshop Manual Ed. 06-2011...
  • Page 151 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Front fork 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...
  • Page 152 FRONT SUSPENSION CR 125 2011 - WR 125 2011 remove the brake calliper from the L.H. fork leg loosening the two retaining screws (3); remove the front wheel as described in Section "Y"; H06807 loosen the bolts (4) that secure the fork legs to steering head and bottom yoke;...
  • Page 153 FRONT SUSPENSION CR 125 2011 - WR 125 2011 H06813 Front fork overhaul Front suspension (CR) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. 1) Bottom yoke with pin...
  • Page 154 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Front fork disassembly (CR) Loosen the cap nut at the top of each outer tube. it is good practice to moderately slacken the cap nuts before remov- ing the fork legs from the motorcycle H06813 Drain oil from the damper unit.
  • Page 155 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Take the cartridge out of the outer tube. H06821 Do not remove the nut at the bottom end of the cartridge. H06822 Remove the bottom valve assembly from the cartridge. Hold the cartridge octagonal nut with the suitable tool to prevent rotation.
  • Page 156 FRONT SUSPENSION CR 125 2011 - WR 125 2011 If outer tube and inner tube are still assembled together, place the fork leg upside down and allow at least 20 minutes for oil to drain. H06825 Remove the dust seal using a flat head screwdriver.
  • Page 157 FRONT SUSPENSION CR 125 2011 - WR 125 2011 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. H06829 Check the rebound adjuster rod for distortion or damage.
  • Page 158 FRONT SUSPENSION CR 125 2011 - WR 125 2011 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 sliding the sealing ring over the inner tube, cover tube edge with plastic as shown in the figure.
  • Page 159 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Fit the dust seal to the outer tube. Make sure that there is not play between dust seal and outer tube. H06839 Refit the cartridge. Tighten the nut all the way onto the rebound adjuster rod.
  • Page 160 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Pull the piston rod until fully extended. Check oil level. It should be about 145 mm (5.7 in.). H06843 Push the piston rod all the way down and install the bottom valve assembly.
  • Page 161 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Drain excess oil from the cartridge pushing the damper unit all the way home. Be careful not to distort or damage the piston rod or any other parts. Please note that excess oil may flow out from the hole located before the reservoir.
  • Page 162 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Push down the inner tube. Slip the tool shown in the figure between wheel axle carrier and cartridge nut. Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw.
  • Page 163 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm (40.5 ft/lb). H06819 Fill the outer tube with the specified quantity of oil (352 cm H06855 Tighten the cylinder onto the outer tube to 29 Nm (21.4 ft/lb).
  • Page 164 FRONT SUSPENSION CR 125 2011 - WR 125 2011 H07074 Front suspension (WR) Front suspension is handled by a KAYABA upside-down telescopic hydraulic fork with advanced axle and 48 mm legs. Wheel travel is 300 mm. 1) Bottom yoke with pin...
  • Page 165 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Loosen the cap nut at the top of each outer tube. it is good practice to moderately slacken the cap nuts before remov- ing the fork legs from the motorcycle). H06862 Loosen the fork cap nut and the nut with a wrench.
  • Page 166 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Remove nut, spring guide, O-ring and collar bushing. H06870 Hold the cartridge top end steady. Loosen and remove the bottom valve assembly. H06871 Workshop Manual Ed. 06-2011 I.18...
  • Page 167 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Take the cartridge out of the outer tube. H06868 Remove the dust seal using a flat head screwdriver. H06869 Workshop Manual Ed. 06-2011 I.19...
  • Page 168 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Remove the retaining ring using a flat head screwdriver. H06873 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.
  • Page 169 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Check the spring. Replace it if: outside diameter is damaged or exceedingly worn. Free length is 460 mm (18.11 in.) or less. H06878 Check the inner tube. Replace if distorted. (Never attempt to repair or reuse a distorted fork tube).
  • Page 170 FRONT SUSPENSION CR 125 2011 - WR 125 2011 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.
  • Page 171 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Insert the cartridge into the outer tube. H06868 Hold the cartridge top end into place. Tighten the bottom valve assembly to 55 Nm (40.5 ft/lb). H06871 Workshop Manual Ed. 06-2011 I.23...
  • Page 172 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Fit collar bushing, O-ring, spring guide and nut onto piston rod. Insert the rebound adjuster rod into the piston rod. Make sure that at least an 18 mm (0.71 in.) portion of the rebound adjuster rod protrudes from the piston rod.
  • Page 173 FRONT SUSPENSION CR 125 2011 - WR 125 2011 Filling oil to specific level Fill the damper unit with oil up to the top edge of the outer tube. Slowly pump the outer tube up and down to help oil flow equally into both inner and outer tube.

  • Page 175: Rear Suspension

    REAR SUSPENSION CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 176 REAR SUSPENSION CR 125 2011 - WR 125 2011 Rear shock 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: Rear Shock Absorber

    REAR SUSPENSION CR 125 2011 - WR 125 2011 Rear shock absorber TIGHTENING TORQUE FIGURES 44 ÷49 Nm/ 4.4 ÷4.5 Kgm/ 32.5-36.2 H/Lb H06892 H06891 Lubrication points (grease) Workshop Manual Ed. 06-2011...
  • Page 178 REAR SUSPENSION CR 125 2011 - WR 125 2011 Rear suspension The rising-rate rear suspension is made up of a 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.

  • Page 179: Rear Shock Absorber Removal

    REAR SUSPENSION CR 125 2011 - WR 125 2011 Rear shock absorber removal Fit a support under the engine so that the rear wheel is raised off the ground. Remove rear chassis, as described in paragraph E - General Procedures.

  • Page 180: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION CR 125 2011 - WR 125 2011 Disassembling and servicing the swinging arm Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Remove secondary drive chain (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).
  • Page 181 REAR SUSPENSION CR 125 2011 - WR 125 2011 Remove plastic (8) by cutting clamp (9) and plastic (10) by cutting clamp (11) and loosening screw (12). H06901 Using a 22 mmm wrench, loosen nut (13) on the left side, and remove pin (14) on the opposite side.

  • Page 182: Servicing The Swinging Arm Shaft

    REAR SUSPENSION CR 125 2011 - WR 125 2011 Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion.

  • Page 183: Brakes

    BRAKES CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 184 BRAKES CR 125 2011 - WR 125 2011 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..................

  • Page 185: Braking System

    BRAKES CR 125 2011 - WR 125 2011 Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3.

  • Page 186: Brake Disc

    BRAKES CR 125 2011 - WR 125 2011 Brake disc Checking the brake disc is an important safety procedure; the disc must be spot- less, i.e. free from corrosion, oil or other dirt or deep scoring. Front brake disc diameter: 260 mm (10,236 in.) Front brake disc thickness (when new): 3,0 mm (0,12 in.)

  • Page 187: Checking Brake Pads For Wear / Replacing The Pads

    BRAKES CR 125 2011 - WR 125 2011 Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit ”A” 3.8 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs.

  • Page 188: Bleeding The Front Braking System

    BRAKES CR 125 2011 - WR 125 2011 Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: 1) Take the rubber cap off the bleed valve (1).

  • Page 189: Bleeding The Rear Braking System

    BRAKES CR 125 2011 - WR 125 2011 Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding. Bleeding procedure is as follows: 1) Remove reservoir cap (A) (21 mm wrench) and diaphragm and fill with fluid (DOT 4).

  • Page 190: Changing The Fluid

    BRAKES CR 125 2011 - WR 125 2011 Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind.
  • Page 191 BRAKES CR 125 2011 - WR 125 2011 3) Remove the reservoir cap (2) or (2A, 21 mm wrench) and the rubber gaiter and fill the reservoir with fresh fluid. 4) Loosen the bleed valve (1) or (1A) and operate the brake lever (3) or the brake pedal (3A) repeatedly until draining all fluid.
  • Page 192 BRAKES CR 125 2011 - WR 125 2011 Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): replace worn or cracked hoses. H06910 H06911 Workshop Manual Ed. 06-2011 L.10...

  • Page 193: Removal Of The Rear Braking System

    BRAKES CR 125 2011 - WR 125 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.

  • Page 194: Removal Of The Front Braking System

    BRAKES CR 125 2011 - WR 125 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). H06913 Loosen the two screws (5) and disconnect the brake calliper (6).
  • Page 195 BRAKES CR 125 2011 - WR 125 2011 Release the hose (7) from the support (8). H07013 H06914 Disconnect the STOP microswitch connector (9). H07014 Loosen the two screws (10) (6 mm wrench) and remove the brake lever (11) complete with pump and tank.

  • Page 197: Electrical System

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 198 ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Wiring diagram (CR) .................. M.3 Key to wiring diagram ................M.3 Colour coding key ..................M.3 Wiring diagram (WR) ................. M.4 Key to wiring diagram ................. M.4 Colour coding key ..................M.4 Electrical component location (CR) ............

  • Page 199: Wiring Diagram (Cr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Wiring diagram (CR) H07071 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 ....

  • Page 200: Colour Coding Key

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Wiring diagram (WR) H06923 Key to wiring diagram Colour coding key 16. Rear R.H. turning indicator 17. Spark plug 1. Transducer B ....Blue 18. Horn controller 2. Speed sensor Bk ....Black 3.

  • Page 201: Electrical Component Location (Cr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Electrical component location (CR) H06924 The ignition system includes the following elements: Generator (1), in oil bath, on the inner side of L.H. crankcase cover; H06925 Spark plug (2) on the cylinder head;...

  • Page 202: Electrical Component Location (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Electrical component location (WR) H06924 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.
  • Page 203 ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Headlamp (6) with two filaments bulb of 12V-35/35W and parking light bulb H06929 of 12V-5W; H06930 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: Checking Generator Stator Windings Resistance (Cr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Checking generator stator windings resistance (CR) H06932 The generator consists of a 12 V alternator with a power of 500 at 10.000 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.

  • Page 205: Checking Generator Stator Windings Resistance (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Checking generator stator windings resistance (WR) The generator consists of a 12 V alternator with a power of 300 W at 10.000 rpm, positioned inside engine left side cover. H06947 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.

  • Page 206: Alternator Inspection

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Alternator inspection Disconnect the three yellow cables coming from the alternator from the regulator, taking care to properly insulate them so as not to let them contact each other. Take engine to approx. 3,000 rpm, and measure the open-circuit voltage using an alternate current voltmeter with a scale up to at least 50V.

  • Page 207: Electronic Ignition System (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 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 H06965 Workshop Manual Ed. 06-2011...

  • Page 208: Voltage Regulator

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 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. H02545 H06962 Workshop Manual Ed. 06-2011 M.12...

  • Page 209: Checking Coil Windings Resistance (Cr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Checking coil windings resistance (CR) Remove saddle and fuel tank (see relevant paragraph) to gain access to the coil (1). Disconnect the coil connector from the wiring, remove retaining screws and coil, and measure resistance in the primary and secondary windings with a meter.

  • Page 210: Transducer (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Transducer (WR) The transducer (1) is located on the left side, secured to a special bracket. H06937 H06499 Electronic control unit (ECU) (CR) The control unit (1) is located on the left side, under the fuel tank.

  • Page 211: Spark Plug

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Spark plug Spark plug (1) is a "CHAMPION QN84/NGK BR9EG". Check electrode gap "A" (0.6 mm). A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed. Clean off any dirt around spark plug base before removing the spark plug. It is good practice to closely inspect the...

  • Page 212: Timing Curve

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

  • Page 213: Headlight Unit With Front Fairing Removal (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Headlight unit with front fairing removal (WR) Using an 8 mm wrench, loosen screw (1). H06940 Move headlamp fairing (2) forward, and lift it to release damping pads (3) from their mounts (4).

  • Page 214: Removing Headlight From Front Fairing (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 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). H02565 Disconnect headlight connector (2). Widen the supporting tabs (3), and remove headlight (4) from the inside.

  • Page 215: Front Turning Indicator Removal (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Front turning 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.

  • Page 216: Headlamp, Tail Light (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 HEADLAMP, TAIL LIGHT (WR) Headlamp adjustment (WR) The headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light. Beam setting needs to be performed accurately;...

  • Page 217: Tail Light Replacement (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 release the bulb holder clips (3) and take out bulb (4); H02570 Headlamp bulb (4) is of the halogen type (H4); be careful when replacing it since the glass part shall not be touched with bare hands.

  • Page 218: Number Plate Bulb Replacement (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Number plate bulb replacement (WR) - Loosen screw (1) and remove the number plate bulb (2) from the mud- guard. H02574 - Extract the bulb holder (3) with the bulb (4) from the housing.

  • Page 219: Rear Turning Indicator Removal (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Rear turning indicator 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. H02575 Slide turning indicator cables out of rubber gaiter (3).

  • Page 220: Rear Wiring Harness Replacement (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Rear wiring harness replacement (WR) Remove the left body panel as outlined in section E. Remove the tail light as outlined in the relevant paragraph. Disconnect connector (1) and cut clamps securing wiring harness to chas- sis.

  • Page 221: Colour Coding Key

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 H07017 G-Bk G-Bk W-Bk B-Bk H07018 Colour coding key B ....Blue Gr ....Grey Y ....Yellow Bk ....Black R ....Red B-Bk ....Blue-Black Sb ....Sky blue G ....

  • Page 222: Semiconductor Parts

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 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. Workshop Manual Ed. 06-2011 M.26...

  • Page 223: Digital Dashboard, Warning Lights (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 DIGITAL DASHBOARD, WARNING LIGHTS (WR) The motorcycle is equipped with a digital instrument; on the instrument are located 2 warning lights too: high beam and blinkers. 1- BLUE warning light “HIGH BEAM”...
  • Page 224 ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 2- SPEED / CLOCK (figure 2) - SPEED: motorcycle speedmaximum value: 299 Km/h o 299 mph; - CLOCK: clock- Reading from 0:00 to 23:59:59; To reset the clock, push the knob SCROLL (A) for more than 3 seconds in order to increase the hours;...

  • Page 225: Dashboard Replacement (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Dashboard replacement (WR) H06942 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).

  • Page 226: Troubleshooting

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 TROUBLESHOOTING ELECTRONIC IGNITION SYSTEM A weak or missing spark might be a symptom of: 1) incorrect connections in the electrical system; 2) faulty spark plug or wrong heat rating or incorrect spark plug gap (see para- graph "Spark plug");...

  • Page 227: Front Side, Under Headlamp Fairing (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Front side, 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)

  • Page 228: Rear Side, Under Tail Light (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Rear side, under tail light (WR) Tail light connector (15) H06983 Number plate light connector (16) Rear right-hand turning indicator connectors (17) Rear left-hand turning indicator connectors (18) H06984 Workshop Manual Ed. 06-2011...

  • Page 229: Securing The Wiring Harness (Wr)

    ELECTRICAL SYSTEM CR 125 2011 - WR 125 2011 Securing the wiring harness (WR) Bike main wiring harness consists of a main branch connecting transducer, voltage regulator, flasher, 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.
  • Page 230 ELECTRICAL SYSTEM CR 125 2011 - WR 125 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).

  • Page 231: Engine Cooling

    ENGINE COOLING CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 232 ENGINE COOLING CR 125 2011 - WR 125 2011 Coolant level check ..................N.3 Cooling circuit (CR) ..................N.4 Cooling circuit (WR) ..................N.5 Engine cooling system overhaul ..............N.6 Workshop Manual Ed. 06-2011...

  • Page 233: Coolant Level Check

    ENGINE COOLING CR 125 2011 - WR 125 2011 Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system.

  • Page 234: Cooling Circuit (Cr)

    ENGINE COOLING CR 125 2011 - WR 125 2011 Cooling circuit (CR) H06918 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Head/radiators upper pipe...

  • Page 235: Cooling Circuit (Wr)

    ENGINE COOLING CR 125 2011 - WR 125 2011 Cooling circuit (WR) H06920 The forced circulation cooling system uses a centrifugal pump (located to the left of the head) and two down-draft radiators. Radiator cap Right-hand radiator Left-hand radiator Fitting...

  • Page 236: Engine Cooling System Overhaul

    ENGINE COOLING CR 125 2011 - WR 125 2011 Engine cooling system overhaul If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator.

  • Page 237: Special Tools

    SPECIAL TOOLS CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 238 SPECIAL TOOLS CR 125 2011 - WR 125 2011 SPECIAL TOOLS (8000 46613) Flywheel puller (CR) (8000 60516) Flywheel puller (WR) (8000 79831) Ignition phase control tool (CR) (8000 86950) Ignition phase control tool (WR) (8000 89030) Crankcase bearing puller...

  • Page 239: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES CR 125 2011 - WR 125 2011 Section Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work 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 after cleaning the threads with solvent. Workshop Manual Ed. 06-2011...
  • Page 240 TIGHTENING TORQUE FIGURES CR 125 2011 - WR 125 2011 ENGINE APPLICATION THREAD N.m. ft/lb Cylinder ret. stud bolt (+LOCTITE 243) M8x1.25 19.6÷21.6 2.0÷2.2 14.5÷15.9 Cylinder lock. nut M8x1.25 17.6÷19.6 1.8÷2.0 13.0÷14.5 Head lock. nut M8x1.25 17.6÷19.6 1.8÷2.0 13.0÷14.5 Pulley ret. screw M5x0.8 5.1÷5.7 0.52÷0.58 3.8÷4.2 Cylinder ret. stud bolt (+LOCTITE 243) M8x1.25 19.6÷21.6 2.0÷2.2 14.5÷15.9 Primary shaft plate ret. screw...
  • Page 241 TIGHTENING TORQUE FIGURES CR 125 2011 - WR 125 2011 Application Thread ft/lb Upper rear chassis ret. screw M8x1.25 24.5÷26.5 2.5÷2.7 18.1÷19.5 Rear chassis lower ret. screw M8x1.25 24.5÷26.5 2.5÷2.7 18.1÷19.5 Chain roller ret. screw M8x1.25 25.5÷28.5 2.6÷2.9 18.8÷21 Engine front ret. screw M8x1.25 33.3÷37.3 3.4÷3.8 24.5÷27.5 Engine lower ret. screw...
  • Page 242 TIGHTENING TORQUE FIGURES CR 125 2011 - WR 125 2011 Application Thread ft/lb Upper chain guide ret. screw (WR) M8x1.25 23.3÷26.5 2.4÷2.7 17.3÷19.5 Rear chain guide ret. screw (CR) M6x1 14÷15.4 1.43÷1.57 10.3÷11.3 Front chain guide ret. screw (CR) M8x1.25 12.2÷13.3 1.24÷1.36 9÷9.8 Slider ret. screw M5x0.8 5.6÷6.2 0.57÷0.63 4.1÷4.5 Horn ret. screw (WR) M6x1 10.3÷11.3 1.05÷1.15 7.6÷8.3 Headlight unit ret. screw (WR)
  • Page 243 TIGHTENING TORQUE FIGURES CR 125 2011 - WR 125 2011 Steel screws on plastic, with metal spacers M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb Steel screws on plastic, with metal spacers 4 Nm 0.4 Kgm 3 ft/lb Steel screws on brass, copper, aluminium M5 4 Nm 0.4 Kgm 3 ft/lb Steel screws on iron, steel M5 6 Nm 0.6 Kgm 4.4 ft/lb Steel screws on plastic, with metal spacers 6.5 Nm 0.65 Kgm...

  • Page 245: Chassis And Wheels

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Section Workshop Manual Ed. 06-2011...
  • Page 246 CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.4 Chassis parts check ..................Y.4 Front wheel ....................Y.5 Removing the front wheel ................Y.6 Reassembling the front wheel ..............Y.7 Speed sensor (WR) ..................Y.8 Rear wheel ....................

  • Page 247: Chassis

    CHASSIS AND WHEELS CR 125 2011 - WR 125 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: Lubrication Points (Lubricant)

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Lubrication points (lubricant) 1 Steering bearings (grease) H06809 Chassis parts check H06814 Check the assemblies shown in the figure for cracks or damage. If any are found, replace the part.

  • Page 249: Front Wheel

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Front wheel 8 13 H06832 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...

  • Page 250: Removing The Front Wheel

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. H06856 Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts.

  • Page 251: Reassembling The Front Wheel

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Reassembling the front wheel Fit the L.H. spacer on the wheel hub. H06857 Fit the wheel between the fork legs so as to set the brake disc into the calliper.

  • Page 252: Speed Sensor (Wr)

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Speed sensor (WR) Check the gap “B” between magnet (6) on brake disc and sensor (7) on brake calliper. H02632 Workshop Manual Ed. 06-2011...

  • Page 253: Rear Wheel

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Rear wheel 9 10 H06860 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...

  • Page 254: Removing The Rear Wheel

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 H06867 Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...

  • Page 255: Wheel Servicing

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: place the hub on a flat surface with an appropriate hole (for when you knock out the bearing);...

  • Page 256: Wheel Spokes

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Re- tighten if needed. Improper tightening will affect motorcycle stability; for a quick check, simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear, crisp sound indicates proper tightening, a dull sound means that the spokes need to be tightened.

  • Page 257: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Rear chain sprocket, secondary drive sprocket and chain The figure 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.

  • Page 258: Checking Pinion And Sprockets For Wear

    CHASSIS AND WHEELS CR 125 2011 - WR 125 2011 Checking pinion and sprockets for wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced. Wheel misalignment causes abnormal wear, making the motorcycle unsafe to ride.

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