Table Of Contents - Husqvarna 2004 WR 125 Workshop Manual

Table of Contents

Important Notices4
Useful Suggestions7
General Instructions For Repair Work7
Summary12
General15
Table Of Contents15
Electric System19
Supply19
Type19
Quantity19
Moteur20
Alimentation20
Graissage20
Allumage20
Demarrage20
Transmission20
Freins20
Chassis20
Suspensions20
Roues20
Pneus20
Installation Electrique21
Motor22
Speisung22
Schmierung22
Kühlung22
Zündung22
Anlauf22
Kraftuebertragung22
Bremsen22
Rahmen22
Aufhängungen22
Räder22
Reifen22
Elektrische Anlage23
Nachfuellungen23
Pagina23
Ruedas24
Neumaticos24
Dimensiones24
Capacidades25
A-125 2004 25-08-2003 13:54 Pagina26
Maintenance27
Operazioni Di Preconsegna29
Pre -Delivery Inspection30
Operations De Pré-Livraison30
Vorgänge Zur Auslieferung31
Operaciones De Pre-Entrega31
Esquema De Mantenimiento Periodico35
Troubles And Remedies44
Adjustments61
Lubricación63
Settings And Adjustments64
Checking The Spark Advance64
Compression Ratio Control66
Change Gear And Main Transmission Lubrication68
Cooling Liquid Level Control70
Cooling Liquid Drain And Top Up71
Checking The Fuel Hose72
Replacing Clutch Discs73
Clutch Control Lever Adjustment75
Idling Adjustment76
Throttle Control Cable Adjustment77
Air Filter Cleaning78
Adjusting Front Brake Control Lever80
Rear Brake Pedal Position Adjustment81
Rear Brake Adjustment82
Adjusting The Suspensions According To Particular Track Conditions84
Hard Ground84
Sandy Ground84
Muddy Ground84
Adjusting The Fork88
Compression (Lower Register)88
Standard Calibration88
Extension88
Adjustment Of Steering Bearing Play90
Handlebar Position Change92
Sag Adjustment Of Rear Suspension94
Adjusting The Shock Absorber Spring Preload95
Shock Absorber Damping Adjustment96
Lubricating The Chain100
Chain Tension Adjustment100
Fast Adjustment100
Lubricating The Chain Without Or101
Lubricating The Chain With Or101
Checking The Wear Of Chain, Pinion And Sprocket101
Replacing Muffler Deadening Material108
Checking The Exhaust Pipe108
General Operations109
Saddle Removal112
Removal Of Side Panel112
Removal Of The Fuel Tank And Conveyors113
Exhaust Silencer And Pipe Removal114
Removal Of Rear Frame, Mudguard And Air Filter115
Cooling System Removal116
Removal Of Clutch Control Cable And Carburetor117
Engine Removal118
Engine Disassembly121
Removal Of Components And Cover On The R.h. Side124
Separation Of Half-Crankcases141
Engine Overhauling145
Particulars Cleaning148
Couplings149
Cylinder150
Piston151
Cylinder Piston Assembly152
Piston Pin153
Piston Rings154
Piston Rings - Grooves Play155
Cylinder Piston Rings Play155
Connecting Rod158
Crankshaft159
Crankshaft Out-Of-Axis159
Head160
Checking Straightness Of Various Shafts161
Bearings162
Bearings Replacement163
Seal Rings Replacement163
Clutch Assembly164
Friction Disc Thickness164
Clutch Housing - Friction Disc Clearance165
Friction Disc Distortion165
Free Length Of The Clutch Control Spring165
Gearbox168
Gear Selector Fork169
Fork Sliding End Thickness169
Fork Driving Pin Diameter169
Pilot Jet173
Jet Needle Retainer Position174
Jet Needle175
Throttle Valve Cutaway Size175
Main Jet176
Carburetor Tuning176
How To Judge The Fuel Air Mixture177
Carburetor Adjustment178
Main Jet And Idle Jet Change Related To Altitude And Air Temperature179
Idle Circuit Adjustment180
Main Circuit Adjustment181
Intermediate Circuit Adjustment182
Idle Circuit Final Adjustment182
Throttle Valve Replacement183
Intermediate Circuit Final Adjustment184
Air Filter Box - Carburetor Manifold188
Blade Valve189
Exhaust Valve189
Engine Re-Assembly192
General Directions194
General Fastening195
Reassembly Of Gear Numbers200
Reassembly Of Cylinder And Piston207
Clutch Reasembly211
Reassembly Of Right Cover214
Reassembling The Exhaust Valves215
Frame, Suspensions And Wheels220
Removing The Front Wheel225
Removing The Front Fork227
Fork Exploded View229
Spring Table241
Fork Working242
General Rules For A Proper Overhauling243
Troubleshooting Guide243
Maintenance Recommendations244
Procedure244
Oil Change244
Oil Drain245
Oil Filling246
Oil Seal Change246
Disassembly247
Reassembly247
Stanchion Disassembly249
Rebound Setting Change249
Compression Setting Change249
Slider Plug Disassembly249
Damping Unit Reassembly250
Foot Valve And Damping Unit Reassembly250
Rear Wheel285
Removing The Rear Wheel286
Rear Suspension288
Chain Tension Rollers, Chain Driving Roller, Chain Guide, Chain Runner288
Rear Swinging Fork289
Progressive Links And Shock Absorber289
Rear Damper Removal290
Overhauling The Spring291
Rocking Fork Removal And Overhauling293
Overhauling The Swinging Arm Pivot Pin295
Overhauling Of The Rocking Lever And Of The Rear Suspension Tie Rod295
Wheel Rim Axle Bending298
Spoke Nipples298
Rim Warpage For Front And Rear Wheel299
Rear Ring Gear300
Brakes301
Brake Discs306
Wear Check And Replacement Of Brake Pads308
Front Braking System Bleeding311
Rear Braking System Bleeding311
Legenda Schema Elettrico (Wr)321
Key To Wiring Diagram (Wr)321
Legenda Colore Cavi (Wr)322
Cable Colour Coding (Wr)322
Wiring Diagram "Wr 125 Enduro Usa323
Electric Ignition Equipment (Wr)324
Impianto Accensione Elettronica (Wr)324
Electric Ignition Equipment (Cr)325
Impianto Accensione Elettronica (Cr)325
Electronic Start System (Cr)325
Generator326
Coil326
Digital Power Unit (Cr)326
Alternator Check327
Voltage Regulator328
Spark Plug328
Timing Curve332
Headlamp333
Racing Main Witing Harness (Wr)335
Engine Cooling System338
Check Of The Coolant Level339
Cooling System341
Engine Cooling System Overhauling342
H.t.s. Exhausts Valve344
Check The Position Of The Exhaust Valve344
Optional Parts List345
Specific Tools350
Torque Wrench Settings351
Tampering Warning369
Spark Arrester370