Husqvarna CR 50 / 2011 Workshop Manual
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Husqvarna CR 50 / 2011 Workshop Manual

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Workshop Manual
CR 50 / 2011
SM 50 / 2011
Ed. 01-09-2010

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  • Page 1 Workshop Manual CR 50 / 2011 SM 50 / 2011 Ed. 01-09-2010...
  • 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 ma- nual 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 Workshop Manual CR 50 / 2011 SM 50 / 2011 Copyright by HUSQVARNA MOTORCYCLES S.R.L. BMW Group Technical Service Via Nino Bixio, 8 21024 (Varese) - Italy tel. ++39 0332 75.61.11 tel. ++39 0332 756 558 www.husqvarna-motorcycles.com...
  • Page 4 FOREWORD, TABLE OF CONTENTS 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 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 .........................F Front Suspension ....................I Rear Suspension ....................

  • Page 7: Important Notices

    IMPORTANT NOTICES Section Ed. 01-09-2010...
  • Page 8 * In order to maintain the vehicle’s "Guarantee of Functionality", the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client.

  • Page 9: General Information

    GENERAL INFORMATION Section Ed. 01-09-2010...
  • Page 10 GENERAL INFORMATION Engine ......................A.3 Fuel system ....................A.3 Lubrication ....................A.3 Cooling ......................A.3 Ignition system....................A.3 Starter ......................A.3 Drive and Transmission ................A.3 Chassis ......................A.3 Suspension ....................A.3 Brakes ......................A.3 Wheels......................A.4 Tyres ......................A.4 Electrical components location ..............A.4 Overall dimensions - Weight .................A.5 Capacities .....................A.5 Ed. 01-09-2010...

  • Page 11: Engine

    GENERAL INFORMATION Engine Single cylinder, 2 stroke Bore ......................39.5 mm Stroke ......................40 mm Displacement ..................49 cm Compression ratio ...................7.12:1 Fuel system Carburettor type ............Dell'Orto..PHBG 19 High speed jet....................85 Low speed jet ....................65 Lubrication Engine ..........3% fuel-oil mixture during running-in and 2% after running-in. Crankcase Cooling Liquid, with twin radiator...
  • Page 12 GENERAL INFORMATION Wheels Rims Front ..................in light alloy: 1.5x12” Rear ...................in light alloy: 1.6x10” Front ..................in light alloy: 1.5x10" Rear ...................in light alloy: 1.5x10" Tyres Front ............PIRELLI SCORPION 60/100 12” 36M Rear ............ PIRELLI SCORPION 2.75 -10 37J NHS SM ..........SAVATECH 3.50-10 51P TL MC31 S-RACER Cold tyre pressure Front ....................
  • Page 13 GENERAL INFORMATION Overall dimensions - Weight Kerb weight, without fuel ............43.4 kg (95.6 lb) *: max. width Capacities Type Quantity Fuel tank 3% fuel-oil mixture during running-in, then 2% 2.7 litres Oil inside crankcase SAE 20/30 150 cc (oil change) Front fork oil CASTROL SYNTHETIC FORK OIL - 5W Coolant...

  • Page 15: Maintenance

    MAINTENANCE Section Ed. 01-09-2010...
  • Page 16 MAINTENANCE ENGINE Transmission fluid level check ● ● Transmission fluid change ● ● Engagement speed check ● ● ● Spark plug check and/or change, electrode gap adjustment ● Check of carburettor fixing onto intake manifold ● Check for the presence of cracks on intake manifold ●...
  • Page 17 MAINTENANCE CHASSIS Fork complete maintenance ● Swinging arm mount cleaning and greasing ● Steering bearing and seal cleaning and greasing ● Brake fluid change ● Brake fluid level, pad thickness, brake disc check ● ● Brake hose condition check ● ●...
  • Page 18 MAINTENANCE CHECKS Transmission fluid level check ● Coolant level check ● Brake fluid level check ● Brake seal wear check ● Brake operation check ● ● Control cable lubrication and adjustment ● Fork dust seal removal and cleaning ● Chain cleaning, tensioning check and lubrication ●...

  • Page 19: Troubleshooting

    TROUBLESHOOTING Section Ed. 01-09-2010...
  • Page 20 TROUBLESHOOTING ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression has starting trouble 1. Piston seized Replace 2. Connecting rod small or big end seized Replace 3. Worn piston rings Replace 4. Worn cylinder Replace 5. Cylinder head loosely tightened Tighten 6.
  • Page 21 TROUBLESHOOTING Trouble Cause Remedy Noise seems to come 1. Chain stretched (worn) or improperly adjusted Replace or adjust from the secondary transmission 2. Worn transmission sprockets Replace chain Clutch slips 1. Weak clutch Belleville washers Replace 2. Worn clutch counterweights Replace Clutch is hard to operate 1.
  • Page 22 TROUBLESHOOTING CHASSIS Trouble Cause Remedy Handlebar turns hard 1. Insufficient tyre pressure Inflate 2. Bearing adjuster ring nut or steering stem nut overtightened Adjust 3. Bent steering stem Replace bottom yoke 4. Worn or seized steering bearings Replace Handlebar vibration 1. Bent fork legs Replace 2.
  • Page 23 TROUBLESHOOTING ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy Spark plug fouls 1. Mixture too rich Adjust carburettor setting easily 2. Dirty air filter Clean 3. Worn piston rings Replace 4. Worn piston or cylinder liner Replace Spark plug electrodes 1. Mixture too lean Adjust carburettor setting overheat 2.

  • Page 25: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS Section Ed. 01-09-2010...
  • Page 26 SETTINGS AND ADJUSTMENTS Saddle removal.....................D.4 Tank removal ....................D.4 Chain guard removal ..................D.5 Throttle cable adjustment ................D.5 Carburettor adjustment .................D.6 Idle adjustment .....................D.6 Clutch replacement / setting .................D.6 Front brake fluid level check .................D.9 Front brake lever adjustment ..............D.10 Rear brake pedal adjustment ..............D.11 Rear brake pedal free play adjustment............D.12 Rear brake fluid level check ...............D.12 Oil level check ....................D.13...
  • Page 27 SETTINGS AND ADJUSTMENTS CR 50 H02123 SM 50 H06248 Ed. 01-09-2010...

  • Page 28: Saddle Removal

    SETTINGS AND ADJUSTMENTS Saddle removal Turn the rear fixing (1) counterclockwise. Remove saddle (2) from front retaining screw. H02020 H02021 Tank removal Remove the saddle as described in the relevant paragraph. Close the fuel cock (2) and loosen the clamp (3) on the hose running to the carburettor.

  • Page 29: Chain Guard Removal

    SETTINGS AND ADJUSTMENTS Chain guard removal Cut clips (1), and remove guard (2). Cut clips (3), and remove sprocket guard (4). H02026 Throttle cable adjustment To check the correct adjustment of the throttle cable, operate as follows: move rubber cap (1) at cable end; push and pull cable (2) to make sure it has about 2 mm free play;...

  • Page 30: Carburettor Adjustment

    SETTINGS AND ADJUSTMENTS Carburettor adjustment Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: turn the idle speed adjuster screw (1) located on the left-hand side of the vehicle, until setting idle RPM quite high (turn clockwise to increase the speed and counter clockwise to reduce the speed).
  • Page 31 SETTINGS AND ADJUSTMENTS Using long nose pliers, lock clutch rotation, and undo nut (2) with a 15 mm wrench; H02032 Remove washer (3); H02033 Fit puller (4), by screwing screws (5) inside clutch threaded holes; Screw puller central screw (6) until removing clutch assembly, then remove puller from clutch assembly;...
  • Page 32 SETTINGS AND ADJUSTMENTS Using a 10 mm ring wrench, undo screws (7) securing counterweights (8) to central body; Remove screw (7) with Belleville washers from counterweights (8). To change clutch setting, just vary the position of Belleville washers. It can be Harder or Softer. Clutch setting shall be changed on all the three Belleville washer units.

  • Page 33: Front Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS Front brake fluid level check To check front brake fluid level, proceed as follows: - Position minicross on a flat ground and in vertical position; - Undo screws (1), and remove cover (2) with diaphragm (3); H02042 - check that oil level is about 3 mm from the upper edge;...

  • Page 34: Front Brake Lever Adjustment

    SETTINGS AND ADJUSTMENTS Front brake lever adjustment POSITION ADjUSTMENT Brake lever (1) can be adjusted by loosening screws (2). When finished, tighten screws again (2). H02047 LEvER DISTANCE ADjUSTMENT Lever (1) distance from throttle twistgrip can be adjusted using ring nut (3); turn it clockwise "A"...

  • Page 35: Rear Brake Pedal Adjustment

    SETTINGS AND ADJUSTMENTS 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). turn the cam (2) in order to raise or lower the brake pedal (3) within the range available (A);...

  • Page 36: Rear Brake Pedal Free Play Adjustment

    SETTINGS AND ADJUSTMENTS Rear brake pedal free play adjustment The rear brake pedal (3) should have a free play (B) (5 mm) before the brakes begin to bite. Should this not happen, operate as follows: loosen nut (4); 5 mm operate the pump rod (5) to increase or decrease the free play;...

  • Page 37: Oil Level Check

    SETTINGS AND ADJUSTMENTS Oil level check - Position minicross on a flat ground and in vertical position; - Undo screw (1), and check that oil level skims hole edge. In case of low oil level, top up using a syringe inside level screw hole. H02052 Oil replacement Be careful not to touch hot engine oil.

  • Page 38: Coolant Level Check

    SETTINGS AND ADJUSTMENTS 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 10 mm above the cells. The radiator cap features two locking positions: the first one is for prior discharge of pressure from the cooling system.

  • Page 39: Air Filter Check And Cleaning

    SETTINGS AND ADJUSTMENTS Periodically check the connecting hoses (see "Scheduled Maintenance Chart"): this will avoid coolant leakage and consequent engine seizure. If hoses (A) show cracks, swelling or hardening due to sheaths desiccation, their replacement shall be advisable. Check the correct tightening of the clamps (B). H02057 Air filter check and cleaning - Remove the saddle as described in the relevant paragraph.

  • Page 40: Chain Adjustment

    (1) to the tightening torque of 80 Nm; 8 kgm; 59 ft/lb, and lock screws (3) with check nuts (2). With the chain fully tensioned, insert a suitable shim to check whether chain is slackened. Should this be the case, contact a Husqvarna autho- rised Dealer to have the chain changed. H02061 D.16...

  • Page 41: Chain Lubrication

    SETTINGS AND ADJUSTMENTS 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. Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication.
  • Page 42 SETTINGS AND ADJUSTMENTS Shock absorber adjustment The rear shock absorber must be adjusted to suit rider weight and terrain con- ditions. Proceed as follows: 1. With the bike resting on the ground, without rider, measure distance (A). 2. Sit on the motorcycle in normal riding position with full riding gear on. 3.

  • Page 43: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber spring preload adjustment Proceed as follows: 1. Remove right-hand side panel, as described in the relevant paragraph. 2. Clean lock ring nut (1) and adjuster ring nut (2) of the spring (3). 3. Either with a hook wrench or an aluminium punch, loosen the lock ring nut. 4.

  • Page 44: Shock Absorber Compression And Rebound Damping Adjustment

    SETTINGS AND ADJUSTMENTS Shock absorber compression and rebound damping adjustment Shock absorber rebound stroke can be adjusted. B) REBOUND - Standard setting: 1.25 turns ± 0.25 (from the fully closed posi- tion) To reset the standard setting, turn lower adjuster (1) clockwise until reaching the fully closed position.

  • Page 45: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS 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. Press lightly on the handlebar grips to cause the front end to rotate;...

  • Page 46: Handlebar Position Change

    SETTINGS AND ADJUSTMENTS - Loosen the two bolts (6) securing steering head onto fork legs (use a 6 mm Allen wrench); - Screw ring nut (7) with a 27 mm lowered wrench to the torque of 10 Nm, 3 Kgm, 7.38 ft/lb then increase until reaching a soft steering, without clearan- - Tighten steering head tube nut (5) to 30 Nm, 3 Kgm, 22.13 ft/lb;...

  • Page 47: Fuel Supply Hose Inspection

    SETTINGS AND ADJUSTMENTS Fuel supply hose inspection Check the hose (1) for leaks and replace it as required. Remove the supply hose as described in Section "E". H02075 H02074 Exhaust system check Remove exhaust system components as described in Section "E". Ensure that pipe (1) and silencer (2) do not show any sign of failure or damage: replace if cracked or damaged.

  • Page 49: General Procedures

    GENERAL PROCEDURES Section Ed. 01-02-2010...
  • Page 50 GENERAL PROCEDURES Foreword ......................E.3 Number holder removal ................E.4 Front mudguard removal ................E.4 Saddle removal.....................E.5 Side panel removal ..................E.5 Rear chassis complete with mudguard and air boxremoval ......E.6 Exhaust system removal ................E.8 Scoops and spoiler removal ............... E.11 Transducer removal ..................E.13 Engine removal...................E.14 Rear mudguard with filter box removal ............E.16 Radiator removal ..................E.17...

  • Page 51: Foreword

    GENERAL PROCEDURES 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. H02018 H02077 H02078...

  • Page 52: Number Holder Removal

    GENERAL PROCEDURES Number holder removal Loosen front brake cable guide screw (1). Loosen screw (2) using a 8 mm ring wrench, and lift number holder to remove H02079 Front mudguard removal Loosen the four screws (1) with a 8 mm ring wrench, and remove mudguard (2).

  • Page 53: Saddle Removal

    GENERAL PROCEDURES Saddle removal Turn the rear fixing (1) counterclockwise. Remove saddle (2) from front retaining screw. H02020 H02021 Side panel removal Remove the saddle as described in the relevant paragraph. Loosen the retaining screws (1) and remove the side panels (2) and (3). H02081 Ed.

  • Page 54: Rear Chassis Complete With Mudguard And Air Boxremoval

    GENERAL PROCEDURES Rear chassis complete with mudguard and air box removal Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Remove the fuel tank as described in section "D". Remove the exhaust silencer as described in the relevant paragraph. Slacken the clamp (1) that secures the rubber coupling (2) of the air box at the carburettor end (3).
  • Page 55 GENERAL PROCEDURES Remove pin (7) and subframe (6) with filter box. H02087 H02088 Refit all the disassembled parts in reverse order, making sure to correctly refit rubber union (2) onto carburettor so as to prevent it from sucking not-filtered air. See section "X"...

  • Page 56: Exhaust System Removal

    GENERAL PROCEDURES Exhaust system removal H06257 Remove the saddle as described in the relevant paragraph. Remove the right-hand side panel as described in the relevant paragraph. Loosen the two screws (1) using an 8 mm wrench. H02091 Remove silencer (2) with flexible mount (3). H02090 Ed.
  • Page 57 GENERAL PROCEDURES Disconnect springs (4) from muffler (5). H02092 H02093 Loosen the screw (6) with a 8 mm ring wrench. H02094 Remove muffler (5). H06258 Check seal (7), change if damaged; To make reassembly operations easier, smear some grease onto seal H02096 Ed.
  • Page 58 GENERAL PROCEDURES Reassemble all parts, in the reverse order compared to disassembly. After hooking springs (4), screw muffler (5) and silencer (2) screws, but do not tighten them. H02092 H02093 H06258 Check exhaust system and sleeve (8) exact positions, and then tighten screws.

  • Page 59: Scoops And Spoiler Removal

    GENERAL PROCEDURES Scoops and spoiler removal H06259 Ed. 01-02-2010 E.11...
  • Page 60 GENERAL PROCEDURES Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Loosen the screws (1) using a 8 mm ring wrench and, with a Phillips screw- driver loosen screw (2) and remove scoop (3). Repeat the procedure to remove the other scoop.

  • Page 61: Transducer Removal

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

  • Page 62: Engine Removal

    GENERAL PROCEDURES Engine removal - Remove the fuel tank as described in the relevant paragraph. - Remove the chain as described in the relevant paragraph. - Empty the cooling system as described in the relevant paragraph. - Remove the exhaust system as described in the relevant paragraph. - Loosen clamps (1) and release engine from sleeves.
  • Page 63 GENERAL PROCEDURES - Cut clamp (7), and disconnect stop switch electrical connector (8). H02109 - Disconnect carburettor (9) from intake manifold (10). - With a 10 mm ring wrench on the right side and a 12 mm ring wrench on the left side, remove engine mount rear pins (11).

  • Page 64: Rear Mudguard With Filter Box Removal

    GENERAL PROCEDURES Rear mudguard with filter box removal Remove rear chassis as described in the relevant paragraph. Remove filter with support (1) by pressing the retaining tab (2). H02114 Remove the four screws (3) securing filter box cover (4). (TORX screws) H02115 Using a 8 mm ring wrench, remove the four screws (5) securing rear mud- guard / filter box (6) to subframe (7).

  • Page 65: Radiator Removal

    GENERAL PROCEDURES Radiator removal Remove the fuel tank together with scoops and spoilers as outlined in the relevant paragraphs. Drain coolant as described in the relevant paragraph. Remove the plastic grids (1) from radiators by slightly bending them. H02119 Undo pipe clamps (2). Disconnect pipes (3) from radiators (4).

  • Page 67: Engine

    ENGINE Section Ed. 01-09-2010...
  • Page 68 ENGINE Ignition system values reading........25 ADJUSTMENTS / SETTING ..........3 Stator ................25 CARBURETTOR SETTING ............3 Ignition coil ..............25 Original setting ..............3 Ignition static parameters measurement with Information for setting change ...........3 peak voltage adapter ............25 Basic indications on carburettor wear ........3 ORIGINAL CARBURETTOR SETTING ........26 Idle speed - A..............3 TOLERANCE AND ASSEMBLING CLEARANCES .....26...

  • Page 69: Adjustments / Setting

    ENGINE ADJUSTMENTS / SETTING CARBURETTOR SETTING Original setting Carburettor is originally set for an altitude of approx. 500 m above sea level, a temperature of approx. 20°C, for a mainly offroad use, and for premium gasoline available in the central European area (NO 95), mixed with 2-stroke oil. Information for setting change You shall always start from carburettor original setting, with the following preliminary conditions: perfectly clean air filter, exhaust system and carburettor.

  • Page 70: Valve Opening - B

    ENGINE Valve opening - B Operation with throttle valve during opening. Engine rpm is controlled by idle jet Main jet and by valve shape. If, after idle speed correct adjustment and load reduction, Taper needle engine gallops, emits a lot of smoke and abruptly reaches full power at high rpm when valve is opened, this means that carburetion is too rich, namely that fuel level is too high, or that floater needle is not sealed.

  • Page 71: Cleaning

    ENGINE CLEANING Clean bike at regular intervals so as to keep plastic parts surface in good conditions. We recommend using hot water with a detergent usually available on the market and a sponge. Strong dirt can be removed with a light water jet.

  • Page 72: Engine Removal

    ENGINE ENGINE DISASSEMBLY Engine locking Thoroughly clean engine before disassembly. You can vice engine locking rear support with protective jaws (see pic- ture). Cooling sleeve, intake flange, and ignition coil removal Loosen hose clamps and disconnect water sleeve (2). Slide pin (3) out of ignition coil, remove cap from spark plug. Loosen the 4 screws on intake flange (4);...

  • Page 73: Stator Removal

    ENGINE Stator removal Slide cable guide (1) out of crankcase. Remove TCEI (2) screws from stator (3). Take stator (3) out of crankcase with the utmost care. Cylinder head, cylinder and piston removal Working crossways, undo cylinder head screws, then remove them. Dispose of screw washers, and remove cylinder head (4).

  • Page 74: Crankcase Halves Splitting

    ENGINE Screw puller to rotor with 2 M4x35 screws. Slide out rotor (4) by screwing the jacking bolt. Remove key from keyway. Crankcase halves splitting Undo and remove the seven TCEI screws (5) keeping the two crankcase halves together. Screw puller with two M5x50 screws (7) onto crankcase. With puller installed, separate crankcase halves by screwing the jacking bolt.

  • Page 75: Clutch And Primary Drive Removal

    ENGINE Clutch and primary drive removal Lock engine so as to gain access to clutch side. Remove kick start pedal, and remove the 6 screws (1) from clutch cover. Remove clutch cover, and dispose of seal. Do not remove circlip (2) to prevent kick start pedal shaft from coming out of crankcase and the corresponding spring to cause any dam- age.

  • Page 76: Operations On The Single Parts

    ENGINE OPERATIONS ON THE SINGLE PARTS Read this section at least once before starting the following operations. Then you should define the assembly order so that bearings are installed after crankcase halves have been heated one time only. To force bearings out or, if necessary, using a hammer, the corresponding crankcase half shall be laid (after having removed centring bushings) onto a flat surface wide enough so that the whole mating surface of crankcase half can well rest on it without being damaged.

  • Page 77: Operations On The Left-Hand Side Crankcase Half

    ENGINE Operations on the left-hand crankcase half Remove oil seals (1) and (2), and heat crankcase half onto an electric hob up to approx. 150°C. If, with the crankcase at a temperature of 150 °C, you tap crankcase half on a flat wood board, bearings usually come out of their seats spontaneously.

  • Page 78: Operations On Clutch Cover

    ENGINE Operations on clutch cover Clutch cover shall be removed only if some parts are faulty or if the O-ring has lost is sealing capacity. Turn kick start pedal shaft (1) against spring strength (counterclockwise), and remove starter engagement gear (2), then check teeth for wear. Should it be necessary to remove kick start pedal shaft, remove outer circlip and take kick start pedal shaft out from cover with extreme care.

  • Page 79: Water Pump Overhaul

    ENGINE Water pump overhaul Remove cover (1), and dispose of O-ring. Remove circlip (2) using suitable pliers. Slide water pump impeller (3) out of water pump shaft (4). Pull out water pump shaft (4) and the two bearings (6 and 7). Remove sealing ring (5).

  • Page 80: Piston Check

    ENGINE Reed unit Using a sliding gauge, measure the gap (M) between stop plates. If the measured value does not correspond to the rated value, suitably bend stop plates. Distance M = 17 mm (0.67 in) Piston check If you are reusing a used piston, check the following points: 1.

  • Page 81: Centrifugal Clutch Overhaul

    ENGINE Piston installation clearance LC engine : 0.045 - 0.055 mm (0.0015 - 0.0021 in) REF. PISTON LC CYLINDER 39.455 - 39.460 mm 39.505 - 39.510 mm 1.553 - 1.554 in 1.555 - 1.556 in 39.461 - 39.465 mm 39.511 - 39.515 mm 1.5536 - 1.5537 in 1.5556 - 1.5557 in 39.466 - 39.470 mm...

  • Page 82: Clutch Wear Compensation

    ENGINE Clutch wear compensation Check clutch shoes for wear. If seals show just minor signs of wear, they can be refit. New centrifugal clutch has an outer diameter of approx. 82.5 mm (3.25 in). To compensate for a slight seal wear, you can add one of the preloading washers (6) of each pack between clutch hub and shoes - see figure.

  • Page 83: Engine Reassembly

    ENGINE ENGINE REASSEMBLY Crankshaft and output shaft assembly Heat right-hand side crankcase half on an electric hob. Oil the two bearings, and slightly grease oil seal. Install output shaft and crankshaft inside bearings. Connecting rod shall be positioned almost vertically. Do not force the two shafts inside bearings using a hammer, as this could result in bearings and crankshaft damage.

  • Page 84: Left-Hand Crankcase Half Assembly

    ENGINE Left-hand crankcase half assembly Fit the 2 centring bushings 7x9x10, and install a new seal. Seal is cut to size only after left-hand crankcase installation. Heat left-hand crankcase on an electric hob and assemble it. Screw the 7 TCEI screws. Screws 4, 8 and 10 are M6x40;...

  • Page 85: Ignition Assembly

    ENGINE Ignition assembly Insert key inside crankshaft groove. Fit rotor (2) with washer, counteract with the special tool, secure nut in place with Loctite 243, and tighten to 20 Nm / 2.0 Kgm / 14.75 ft/lb. Special tool pins shall not engage inside rotor threaded holes, as they would cause damage to threads.

  • Page 86: Clutch Cover Assembly

    ENGINE Clutch cover assembly Fit the new gasket, and assemble the clutch cover. Screw clutch cover with 6 screws M6x25 (1), tighten screws to a torque of 10 Nm / 1.0 Kgm / 7.38 ft/lb. Ignition cover Fit centring bushings 7x9x10. Align water pump control drive groove (2) with the corresponding mark (3) on crankshaft.

  • Page 87: Piston Assembly

    ENGINE Piston assembly Secure connecting rod with the wooden support. Oil connecting rod small end bearing, and install it inside connecting rod small end. Lay down piston, the arrow on piston crown indicates exhaust groove direc- tion. Manually slide piston pin inside connecting rod small end, and fit piston pin retaining ring with the open side facing down.

  • Page 88: Cylinder Head Assembly

    ENGINE "X" size adjustment - "X" is the size between piston upper edge and cylinder upper edge, with the cylinder tightened, and the piston at T.D.C. - Adjust "X" size with the utmost care, by placing in-between cylin der bottom gaskets having different thicknesses. If "X"...

  • Page 89: Troubleshooting

    ENGINE TROUBLESHOOTING FAULT CAUSE REMEDY Engine does not start Command error Open fuel cock, top up fuel, open air with the engine cold. Interrupted fuel supply Disconnect fuel pipe from carburettor, put it inside a container, and open fuel cock: if some fuel pours out, clean carburettor if no fuel pours out, check tank breather, and clean fuel cock.
  • Page 90 ENGINE FAULT CAUSE REMEDY Too low engine power Fuel supply partially inter- Blow through fuel duct, and clean carburettor. rupted or pipes not correctly positioned Loss of compression due to Tighten spark plug. a loose spark plug Exhaust pipe bent or faulty Check exhaust pipe for any damage.

  • Page 91: Ignition System Values Reading

    ENGINE FAULT CAUSE REMEDY Gearbox oil coming out of Too much gearbox oil Correct gearbox oil level. breather pipe IGNITION SYSTEM VALUES READING. Stator Disconnect stator connector and, using a digital multimeter, measure stator resistance. Resistance shall be 500 Ω ± 40 Ω at 20°C. There is no need to remove stator to make this reading.

  • Page 92: Original Carburettor Setting

    ENGINE ENGINE - TECHNICAL DATA Primary drive ........Spur gear,16: 57 Z ratio Cooling liquid ......cooling with 0.5 litres, consisting of Engine type ........2-stroke Otto single-cylinder 50% antifreeze, 50% distilled water, at least -25° with reed infeed Air filter ............wet with sponge Bore x stroke ............39.5 x 40 mm Spark plug ....

  • Page 93: Engine Torque Figures

    ENGINE ENGINE TORQUE FIGURES DESCRIPTION SUBJECT VALUES Primary drive sprocket nut M14x1.25 40 Nm Ignition rotor nut M10x1.25 20 Nm Clutch hub nut M10x1.25 Loctite 243 + 35 Nm Cylinder head screw Loctite 243 + 12 Nm TE screw - clutch shoes 15 Nm Cylinder bottom nut 18 Nm...

  • Page 95: Front Suspension

    FRONT SUSPENSION Section Ed. 01-09-2010...
  • Page 96 FRONT SUSPENSION Front fork removal ..................I.4 Fork spring specifications ................I.5 Ed. 01-09-2010...
  • Page 97 FRONT SUSPENSION CR 50 H02123 SM 50 H06248 Ed. 01-09-2010...
  • Page 98 FRONT SUSPENSION 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 and then proceed as follows: H02124 H02125 Remove the screw (1) and the brake line clamp on the left-hand side;...
  • Page 99 FRONT SUSPENSION Loosen the bolts (3) that secure the fork legs to steering head and bottom yoke; Remove the fork legs. Refit fork legs and front wheel as described in Section "Y". Set height "A" back to original value. Fork spring specifications Length = 350 mm ø...

  • Page 101: Rear Suspension

    REAR SUSPENSION Section Ed. 01-09-2010...
  • Page 102 REAR SUSPENSION Rear shock absorber ..................J.3 Rear suspension....................J.3 Rear shock absorber removal ...............J.4 Disassembling and servicing the swinging arm ..........J.5 Servicing the swinging arm shaft ..............J.7 Chain roller, chain guide, chain slider ............J.8 Ed. 01-09-2010...

  • Page 103: Rear Shock Absorber

    REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1-2= 40 Nm/ 4 Kgm/ 29.50 ft/lb H02129 Rear suspension The suspension of this motorcycle consists of a shock absorber and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions.

  • Page 104: Rear Shock Absorber Removal

    REAR SUSPENSION Rear shock absorber removal - Remove the side panels as described in the relevant paragraph. - Using two 14 mm ring wrenches, loosen nuts (1) on shock absorber pins, leaving these latter in their seat. H02134 H02135 - Slightly lift rear wheel, and remove lower pin (2). - Remove upper pin (3), and shock absorber (4).

  • Page 105: Disassembling And Servicing The Swinging Arm

    REAR SUSPENSION 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 the secondary drive chain (1) and detach the rear brake line (2) from the swinging arm (A).
  • Page 106 REAR SUSPENSION - With a 17 mm socket wrench on the left side and a 14 mm socket wrench on the right side, remove nut (6) from swinging arm shaft (7), and then remove swinging arm (A). H02145 H02141 H02142 - Check swinging arm shaft straightness, and slide out spacer (E).

  • Page 107: Servicing The Swinging Arm Shaft

    REAR SUSPENSION Servicing the swinging arm shaft Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion. Service limit: 0.30 mm. Ed.

  • Page 108: Chain Roller, Chain Guide, Chain Slider

    REAR SUSPENSION Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary. Check the chain guide alignment, and remember that a bent element can cause chain early wear. In this case, chain might unwrap from the sprocket.

  • Page 109: Brakes

    BRAKES Section Ed. 01-09-2010...
  • Page 110 BRAKES Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Ed. 01-09-2010...
  • Page 111 BRAKES Braking system The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir. 1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 4.
  • Page 112 BRAKES 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 Front brake disc thickness (when new): ..........3.0 mm Wear limit: ....................2.5 mm Rear brake disc diameter: ..............140 mm Rear brake disc thickness (when new): ..........3.10 mm...
  • Page 113 BRAKES Checking brake pads for wear / replacing the pads Check brake pad wear. Service limit "A" 1 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs. Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.

  • Page 115: Electrical System

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

  • Page 117: Wiring Diagram

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

  • Page 118: Electrical Components Location

    ELECTRICAL SYSTEM Electrical components location The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; H02078 Transducer (2) positioned under fuel tank close to carburettor. H02156 Ed. 01-09-2010...

  • Page 119: Spark Plug

    ELECTRICAL SYSTEM Spark plug Spark plug (1) is a "NGK" BR8ECM. Check electrode gap "A" (0.7 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.

  • Page 120: Handlebar Switches

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

  • Page 121: Important

    ELECTRICAL SYSTEM IMPORTANT Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches; c) Air filter intake; d) Steering head, wheel bearings; e) Rear suspension drag drop link.

  • Page 123: Engine Cooling

    ENGINE COOLING Section Ed. 01-09-2010...
  • Page 124 ENGINE COOLING Coolant level check ..................N.3 Cooling circuit ....................N.4 Engine cooling system overhaul ..............N.5 Ed. 1-09-2010...
  • Page 125 ENGINE COOLING 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. Without cooling medium (water), no heat exchange occurs between cylinder head and radiator.
  • Page 126 ENGINE COOLING Cooling circuit H02161 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 Radiator to head pipe Water pump Breather hose Radiator connecting pipes Radiators to water pump lower pipe Ed.
  • Page 127 ENGINE COOLING 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. Straighten any bent fins to ensure free flow of air.

  • Page 129: Special Tools

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

  • Page 131: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES 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. Ed. 01-09-2010...
  • Page 132 TIGHTENING TORQUE FIGURES CHASSIS CLASS OF RATED TOR- ACCEPT. RES. CODE DESCRIPTION SIZE NOTES MATERIAL QUE (Nm) TORQUE (Nm) Chain roller to chassis Z00062796 retaining screw Lower and upper rear ZA0091697 LOCTITE 243 engine retaining screw Front engine retaining ZB00B2684 LOCTITE 243 screw Z00043928 Engine locknut LOCTITE 243 Chain guide to chassis 60ND02558...
  • Page 133 TIGHTENING TORQUE FIGURES FRONT SUSPENSION CLASS OF RATED TOR- ACCEPT. RES. CODE DESCRIPTION SIZE NOTES MATERIAL QUE (Nm) TORQUE (Nm) Head to damper rods Supplied by retaining screw Marzocchi Handlebar clamp retai- Supplied by ning screw Marzocchi Set at 10N/m, and then loosen until re- 8000H3620 Steering preload nut see notes aching a clearance- free soft steering 8000H3820...
  • Page 134 TIGHTENING TORQUE FIGURES FAIRING AND MUDGUARDS CLASS OF RATED TOR- ACCEPT. RES. CODE DESCRIPTION SIZE NOTES MATERIAL QUE (Nm) TORQUE (Nm) Front mudguard retaining 8000A8423 screw with collar Number holder table 8000A8423 screw with collar Pipe guide self-tapping 8000H0534 screw Rear mudguard front re- 8A00A8421 taining screw with collar Rear mudguard rear TEF ZA0067997 screw...
  • Page 135 TIGHTENING TORQUE FIGURES WHEELS AND BRAKES CLASS OF RATED TOR- ACCEPT. RES. CODE DESCRIPTION SIZE NOTES MATERIAL QUE (Nm) TORQUE (Nm) Z00062726 Front brake disc fixing LOCTITE 243 8A00H2753 Front wheel axle Z00062726 Rear brake disc fixing LOCTITE 243 8000H3835 Sprocket fixing LOCTITE 243 8000H2753 Rear wheel axle Front and rear wheel Z00042023 retaining nut Chain tensioner adjuster 8000H4147 screw...
  • Page 136 TIGHTENING TORQUE FIGURES EXHAUST CLASS OF RATED TOR- ACCEPT. RES. CODE DESCRIPTION SIZE NOTES MATERIAL QUE (Nm) TORQUE (Nm) Damping pad to chassis Z00062727 retaining screw Damping pad to chassis Z00044240 retaining nut Damping pad to muffler Z00062725 retaining screw Z00044240 Silencer retaining nut Z00062729 Silencer retaining screw U00060873 Silencer clip nut COOLING SYSTEM CLASS OF...
  • Page 137 TIGHTENING TORQUE FIGURES NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) 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...

  • Page 139: Chassis And Wheels

    CHASSIS AND WHEELS Section Ed. 01-09-2010...
  • Page 140 CHASSIS AND WHEELS Chassis ......................Y.3 Lubrication points (lubricant) ................ Y.3 Front wheel ....................Y.4 Front wheel removal ..................Y.5 Front wheel installation ................. Y.6 Rear wheel ....................Y.7 Rear wheel removal..................Y.8 Wheel servicing .................... Y.9 Wheel axle warpage ..................Y.9 Axle runout over 100 mm ................

  • Page 141: Chassis

    CHASSIS AND WHEELS 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. Refer to the figure for a quick inspection. Use the dimensions reported below to determine whether the chassis needs realigning or replacing.

  • Page 142: Front Wheel

    CHASSIS AND WHEELS Front wheel H02170 Light alloy wheel hub and rim with high-strength steel spokes. Make, type and size of wheel rims ......light alloy: 1.5x12” Make, type and size of tyre........"Pirelli" Scorpion 60/100 12" 36M Cold tyre pressure ..........1.2 Kg/cm Ed.
  • Page 143 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground. H02165 Loosen nut (1) positioned on left-hand side; H02167 Slide out axle (2) on right-hand side, and remove wheel. H02166 Do not operate the front brake lever when the wheel has been re- moved;...
  • Page 144 CHASSIS AND WHEELS Reassembling the front wheel H02168 Fit the wheel between the fork legs so as to set the brake disc into the calliper. Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully home against the L.H.

  • Page 145: Rear Wheel

    CHASSIS AND WHEELS Rear wheel H02169 Light alloy wheel hub and rim with high-strength steel spokes. Make, type and size of wheel rim ....light alloy: 1.6x10”; Make, type and size of tyre......"Pirelli" Scorpion; 2.75-10 37JNHS Cold tyre pressure .......... 1.5 Kg/cm Ed.
  • Page 146 CHASSIS AND WHEELS Removing the rear wheel Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. H02171 Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2);...

  • Page 147: Wheel Servicing

    CHASSIS AND WHEELS 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 148: Wheel Spokes

    CHASSIS AND WHEELS Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Retighten 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 149: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS 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 150 CHASSIS AND WHEELS 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. Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension.

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