Husqvarna CR 65 2012 Workshop Manual
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Husqvarna CR 65 2012 Workshop Manual

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CR 65 2012
Workshop Manual
Ed. 09-2011

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Summary of Contents for Husqvarna CR 65 2012

  • Page 1 CR 65 2012 Workshop Manual Ed. 09-2011...

  • Page 2: 1St Edition (09-2011

    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 ongoing 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 CR 65 2012 Workshop Manual CR 65 / 2012 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: Workshop Manual

    CR 65 2012 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 65 2012 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 Engine Overhaul ....................

  • Page 7: Important Notices

    IMPORTANT NOTICES CR 65 2012 Section Workshop Manual Ed. 09-2011...

  • Page 8: Workshop Manual

    * 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 Customer bears all part replacement and labour costs needed to respect the maintenance schedule.

  • Page 9: General Information

    GENERAL INFORMATION CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 10 GENERAL INFORMATION CR 65 2012 Engine ......................A.3 Fuel system ....................A.3 Lubrication ....................A.3 Cooling ......................A.3 Ignition system....................A.3 Kick ......................A.3 Primary drive ....................A.3 Gearbox ......................A.3 Secondary drive....................A.3 Drive chain....................A.3 Chassis ......................A.3 Suspension ....................A.3 Brakes ......................A.4 Wheels......................A.4 Tyres ......................A.4 Overall dimensions - Weight .................A.4 Electrical components location ..............A.5...

  • Page 11: Engine

    GENERAL INFORMATION CR 65 2012 Engine Single cylinder, 2 stroke Bore ......................45 mm Stroke ....................40.8 mm Displacement .................. 64.89 cu.cm Compression ratio ..................9.1:1 Fuel system Carburettor type MIKUNI..TM24 Maximum jet ....................240 Minimum jet ....................40 Lubrication Engine ..........fuel-oil mixture at 3% during running-in, at 2% after running-in.

  • Page 12: Brakes

    GENERAL INFORMATION CR 65 2012 Brakes Front Type ............with fixed disc “Wave” type Ø 200 mm hydraulic control and four piston fixed calliper. Rear Type ............with fixed disc “Wave” type Ø 165 mm with hydraulic control and two piston fixed calliper.

  • Page 13: Electrical Components Location

    GENERAL INFORMATION CR 65 2012 Electrical component location The ignition system includes the following elements: Generator on the inner side of L.H. crankcase half cover; Electronic ignition coil on frame RH side; Spark plug on cylinder head; Capacities Type Quantity...

  • Page 15: Maintenance

    MAINTENANCE CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 16 MAINTENANCE CR 65 2012 ENGINE Transmission oil level check ● ● Transmission oil change ● ● Spark plug check and/or replacement, electrode gap adjustment ● Carburettor fastening on intake manifold check ● Check of flange, intake manifold, and filter bellow condition and seal check ●...
  • Page 17 MAINTENANCE CR 65 2012 CHASSIS Fork complete maintenance * ● Shock absorber maintenance * ● Swinging arm support and bearing cleaning and greasing * ● Steering bearings and relevant sealing elements cleaning and greasing * ● Brake/clutch fluid replacement * ●...
  • Page 18 MAINTENANCE CR 65 2012 CHECKS Transmission oil level check ● Coolant level check ● Brake fluid level check ● Brake shoe wear check ● Brake operation check ● ● Control cable adjustment and lubrication ● Chain cleaning, lubrication and tension check ●...

  • Page 19: Troubleshooting

    TROUBLESHOOTING CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 20 TROUBLESHOOTING CR 65 2012 ENGINE Trouble Cause Remedy Engine does not start or Insufficient compression it hardly starts 1. Piston seizure Replace 2. Connecting rod small or big end seized Replace 3. Worn piston rings Replace 4. Worn cylinder Replace 5.
  • Page 21 TROUBLESHOOTING CR 65 2012 Trouble Cause Remedy The noise seems to come 1. Chain stretched or incorrectly adjusted Replace or adjust from the secondary 2. Worn transmission sprockets Replace transmission chain The clutch slides 1. Weak clutch springs Replace 2. Worn clutch plates...
  • Page 22 TROUBLESHOOTING CR 65 2012 CHASSIS Trouble Cause Remedy The handlebar is hard to turn 1. Tyre pressure insufficient 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...
  • Page 23 TROUBLESHOOTING CR 65 2012 ELECTRICAL SYSTEM (see also Section M) Trouble Cause Remedy The spark plug gets dirty 1. Mixture too rich Adjust carburettor easily 2. Dirty air filter Clean 3. Worn piston rings Replace 4. Worn piston or cylinder liner Replace 5.

  • Page 25: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 26 SETTINGS AND ADJUSTMENTS CR 65 2012 Saddle removal.....................D.4 Tank removal ....................D.4 Remove the chain/sprocket cover protection casing ........D.5 Throttle cable adjustment ................D.5 Carburettor adjustment .................D.6 Idle adjustment .....................D.6 Front brake fluid level check ................D.6 Clutch oil level check ..................D.7 Front brake lever adjustment ................D.8 Lever distance adjustment................D.8...
  • Page 27 SETTINGS AND ADJUSTMENTS CR 65 2012 CR 65 Workshop Manual Ed. 09-2011...

  • Page 28: Saddle Removal

    SETTINGS AND ADJUSTMENTS CR 65 2012 Saddle removal Turn the rear pin (1) counterclockwise. Release the saddle (2) from the front retaining screw pin. 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: Remove The Chain/Sprocket Cover Protection Casing

    SETTINGS AND ADJUSTMENTS CR 65 2012 Remove the chain/sprocket cover protection casing Cut the ties (1) and remove the casing (2). Loosen the 3 screws (3) that fasten the sprocket cover to the LH casing (4) and remove the protection.

  • Page 30: Carburettor Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 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 CR 65 2012 A decrease of the fluid level will let air into the system, hence an extension of the lever stroke. If the brake lever feels mushy when pulled, there may be air in the brake line or the brake may be defective: CHECK THE BRAKING SYSTEM (see Section "L").

  • Page 32: Front Brake Lever Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 Front brake lever adjustment POSITION ADjUSTMENT Loosen the screws (2) to adjust the lever (1) position. When finished, tighten the screws (2) again. Lever distance adjustment To adjust the distance between the lever (1) and the throttle twistgrip work on the ring nut (3) by turning it clockwise "A"...

  • Page 33: Rear Brake Pedal Position Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 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 34: Rear Brake Fluid Level Check

    SETTINGS AND ADJUSTMENTS CR 65 2012 Rear brake fluid level check The fluid level that can be seen through the inspection window (1) must be above the minimum mark on the master cylinder tank. To restore the level loosen the two screws (2), remove the cover (3), and top-up with oil type specified in the "LUBRICATION AND SUPPLIES"...

  • Page 35: Oil Level Check

    SETTINGS AND ADJUSTMENTS CR 65 2012 Oil level check - Heat up the engine, then turn it off, wait 2 minutes for transmission oil to properly widespread. - Set the minibike on its stand so it is upright and level.

  • Page 36: Coolant Level Check

    SETTINGS AND ADJUSTMENTS CR 65 2012 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 37: Air Filter Cleaning And Check

    SETTINGS AND ADJUSTMENTS CR 65 2012 Air filter check and cleaning - Remove the saddle as outlined in the relevant paragraph. - Remove the plastic cover (1) by loosening the rear chassis retaining screw (2). Release the spring (3) to remove the air filter (4).

  • Page 38: Chain Adjustment

    (1) to a torque 85 Nm; 8.7 kgm; 62.7 ft/lb, and lock the screws (3) using check nuts (2). When keeping the chain as tensioned as possible and inserting the drill rod you notice that the chain gets loosen, contact a Husqvarna authorised Dealer to replace it. Workshop Manual Ed. 09-2011...

  • Page 39: Chain Lubrication

    SETTINGS AND ADJUSTMENTS CR 65 2012 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 40: Fork Position Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 Fork position adjustment - Loosen the two screws (1) onto bottom yoke. - Loosen the steering head screw (2). - Adjust one fork leg at a time. Refer to the notches on the leg upper part to adjust the fork position according to the rider height and the riding needs.

  • Page 41: Shock Absorber Spring Preload Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 Shock absorber spring preload adjustment Proceed as follows: 1. Remove the side panels as described in Section "E". 2. Loosen the two upper screws (4) and remove the two lower screws (5) that fasten the rear chassis to the frame.

  • Page 42: Shock Absorber Hydraulic Damping Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 Shock absorber damping adjustment It is possible to adjust the rebound travel of the shock absorber. A) REBOUND - Standard setting: 2 turns (from fully closed) To reset the standard setting, turn lower adjuster screw (1) clockwise until reach- ing fully closed position.

  • Page 43: Steering Bearing Clearance Adjustment

    SETTINGS AND ADJUSTMENTS CR 65 2012 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 44 SETTINGS AND ADJUSTMENTS CR 65 2012 Afterwards remove the lower ones (3) by loosening the relevant retaining screws (4). Use one of the two holes (5) on the steering head to move the handlebar on or back (of nearly 17 mm - 0.67 in.).

  • Page 45: Tank Supply And Breather Pipe Check

    SETTINGS AND ADJUSTMENTS CR 65 2012 Tank supply and breather pipe check Make sure the pipes (1) and (2) do not feature any leakage, cut, or evident cracks, and in case replace them. Replace the supply pipe (1) as described in section "E".

  • Page 46: Sound Deadening Material Replacement

    SETTINGS AND ADJUSTMENTS CR 65 2012 Sound deadening material replacement Remove the silencer (1) as described in the relevant paragraph and fasten it on a suitable support (vice provided with aluminium protections) having care not to deform the pipe. Remove screws (2) that retain the rear end cap (3) and remove it from the silencer body.
  • Page 47 SETTINGS AND ADJUSTMENTS CR 65 2012 Refit the external pipe having care to seal the front end cap with high-temperature resistant silicone. Apply some sealant (6) on the rear end cap too, and position the latter by starting the retaining screws (2) WITHOUT TIGHTENING THEM COMPLETELY.

  • Page 49: General Procedures

    GENERAL PROCEDURES CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 50 GENERAL PROCEDURES CR 65 2012 Foreword ......................E.3 Number holder removal ................E.4 Front mudguard removal ................E.4 Saddle removal.....................E.5 Side panel removal ..................E.5 Rear chassis with rear mudguard and air filter removal .........E.6 Exhaust system removal ................E.7 Fuel tank removal ..................E.9 Carburettor removal from the engine............E.10 Spark plug cap removal ................E.10...

  • Page 51: Foreword

    GENERAL PROCEDURES CR 65 2012 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 52: Number Holder Removal

    GENERAL PROCEDURES CR 65 2012 Number holder removal Loosen the screw (1) with an 8 mm wrench and lift the Number holder to remove it. Widen the cable ring (2) to release the engine stop cable (4) and the front brake transmission (3).

  • Page 53: Saddle Removal

    GENERAL PROCEDURES CR 65 2012 Saddle removal - Turn the rear pin (1) counterclockwise. - Release the saddle (2) from the front retaining screw pin. Side panel removal Remove the saddle as described in the relevant paragraph. To remove the side panels of the vehicle it is necessary to first remove the plastic cover (1) of the air box, loosening the rear chassis retaining screw (2).
  • Page 54 GENERAL PROCEDURES CR 65 2012 Rear chassis complete with mudguard and air filter removal Remove the saddle as described in the relevant paragraph. Remove the side panels as described in the relevant paragraph. Slacken the clamp (1) that secures the rubber coupling (2) of the filter box at the carburettor (3).

  • Page 55: Exhaust System Removal

    GENERAL PROCEDURES CR 65 2012 Exhaust system removal Expansion pipe/silencer Gasket Springs Elastic supports Coupling Silencer 10 Silencer support Use an 8 mm ring wrench (screw) and a 10 mm key (nut) to remove the screw and the nut to release the silencer (9) from the support bracket (10) (it is not necessary to remove the Number holder).
  • Page 56 GENERAL PROCEDURES CR 65 2012 Remove the silencer (9) by sliding it from the rear side as shown in the figure. Pay attention to the rubber connection coupling (8). - Remove the springs (3) from the silencer (1). Use an 8 mm ring wrench to remove the screw (7) from the elastic support fastened on the chassis.

  • Page 57: Fuel Tank Removal

    GENERAL PROCEDURES CR 65 2012 - Check conditions of gasket (2) and if damaged replace it. For easier assembly smear some grease on the gasket (5). - To reassemble, reverse the above procedure. - See Section "X" for tightening torque figures.

  • Page 58: Carburettor Removal From The Engine

    GENERAL PROCEDURES CR 65 2012 Carburettor removal from the engine - Loosen the tie (1) and remove the carburettor from the intake fitting. Spark plug cap removal - Take off the spark plug cap (1). Radiator removal - Remove the grids from the two radiators (1) releasing the pins from the holes as shown in the figure.
  • Page 59 GENERAL PROCEDURES CR 65 2012 - Loosen the clamp (4) of the upper pipe that connects the RH radiator (the pipe passes through the chassis). If you need to remove the RH radiator with its connection pipe make sure to keep the washer.

  • Page 60: Swinging Arm Removal

    GENERAL PROCEDURES CR 65 2012 - Release the radiator breather hose (3) from the two chassis connection rub- ber clamps (4). At this point, if the LH radiator had been previously removed, remove the two screws (5) that fasten the radiator to the chassis by releasing the RH radiator and the two pipes connecting it to the LH radiator, the pipe to the water pump, and the breather hose on the plug.

  • Page 61: Secondary Drive Chain Removal

    GENERAL PROCEDURES CR 65 2012 - After releasing the brake pedal (B) loosen the chassis retaining screw (4), using a 17 mm socket wrench on the left, and a 14 mm one on the right to remove the nut (2) of the swinging arm pivot (3) and the swinging arm (A) itself.
  • Page 62 GENERAL PROCEDURES CR 65 2012 Generator cable disconnection - Cut the tie (1) that retains the cables against the chassis. Disconnect the generator electric cable connector (2). Engine removal from the chassis - Remove the two front screws (1) that retain the engine to the chassis.

  • Page 63: Engine Disassembly

    ENGINE DISASSEMBLY CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 64 ENGINE DISASSEMBLY CR 65 2012 Preparation ....................F.3 Gearbox oil drainage procedure ..............F.3 Cylinder head, cylinder and piston removal...........F.3 Water pump disassembly ................F.4 Clutch cover removal ..................F.5 Clutch disassembly..................F.5 Primary drive sprocket removal ..............F.6 Kick start pedal shaft removal ...............F.7 Gearbox control shaft and selector plate removal .........F.7 Intake flange and reed valve removal............F.8...

  • Page 65: Preparation

    ENGINE DISASSEMBLY CR 65 2012 Preparation – Clean the engine before disassembling it. – Fasten the engine into the installation stand. – Remove the kick start pedal and the gearbox lever. – Remove the gearbox breather pipe from the engine casing.

  • Page 66: Water Pump Disassembly

    ENGINE DISASSEMBLY CR 65 2012 – Cover the crankcase with a clean cloth and place the piston on a wood sup- port. – Remove the piston pin retainers and gently push it out of the piston. – Lift up the piston and remove the pin bearing from the connecting rod small end.

  • Page 67: Clutch Cover Removal

    ENGINE DISASSEMBLY CR 65 2012 Clutch cover removal – Loosen the clutch cover screws to remove the cover and its gasket. WARNING: When removing the clutch cover, pay attention to the thrust washer (3) of the kick start pedal shaft (it may remain attached to the clutch cover and the water pump shaft spring, page F4, spring (B)).

  • Page 68: Primary Drive Sprocket Removal

    ENGINE DISASSEMBLY CR 65 2012 – Remove the plate pack (2) from the clutch housing. WARNING: The plate pack consists of lined and steel plates, compression springs, spring retaining plate with screws, pressure plate and hub. If no repairing is required on the plate pack, then you do not need to continue disassembling.

  • Page 69: Kick Start Pedal Shaft Removal

    ENGINE DISASSEMBLY CR 65 2012 Kick start pedal shaft removal – Loosen the two screws (1) and remove the stop plate (2). – Remove the kick start pedal shaft from the casing. Gearbox control shaft and selector plate removal – Use a screwdriver to push back the sliding plate (3) and at the same time slide the gearbox control shaft out of the crankshaft.

  • Page 70: Intake Flange And Reed Valve Removal

    ENGINE DISASSEMBLY CR 65 2012 Intake flange and reed valve removal – Loosen the 4 screws (1) of the intake flange and remove the flange with relevant reed valve and gasket. Ignition system disassembly – Loosen the 3 screws of the ignition cover and remove the latter (1).

  • Page 71: Chain Sprocket Removal

    ENGINE DISASSEMBLY CR 65 2012 Chain sprocket removal – Remove the circlip (1) and slide the chain sprocket out of the output shaft. – Slide the spacing bushing out of the output shaft using needle-nose pliers. Splitting the crankcase – Turn up the ignition side and remove all screws from the casing.

  • Page 72: Process

    ENGINE DISASSEMBLY CR 65 2012 Process – Slide out the two gearbox shafts from the right crankcase half. WARNING: when removing the two gearbox shafts pay attention to the output shaft thrust washer which could be stuck inside the casing.

  • Page 73: Engine Overhaul

    ENGINE OVERHAUL CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 74 ENGINE OVERHAUL CR 65 2012 Engine crankcase (crankcase half) ..............G.3 Actions on left crankcase half ...............G.4 Actions on right crankcase half..............G.5 Crankshaft measurement ................G.6 Actions on clutch cover.................G.6 Water pump disassembly and inspection .............G.7 Piston check ....................G.8 Piston ring gap measurement...............G.8 Piston and cylinder measurement, piston assembly clearance determination................G.8...
  • Page 75 ENGINE OVERHAUL CR 65 2012 Crankcase (crankcase half) Warning: Carefully read this paragraph before starting the operation. Determine the reassembly sequence in order carry out a single heating treatment on the crankcase halves to refit the bearings. To detach or remove the bearings - if necessary even tapping with suitable tools - remove the reference bushings and place the crank- case halves on a flat surface big enough to avoid damaging the sealing surfaces of the crankcase halves.
  • Page 76 ENGINE OVERHAUL CR 65 2012 Actions on left crankcase half Remove the oil seals and heat the crankcase half on an electric plate up to 150 °C. WARNING: Gently tap on crankcase half heated to 150 °C on a wood plate to make the bearings fall into their seats.
  • Page 77 ENGINE OVERHAUL CR 65 2012 Actions on right crankcase half Remove the oil seals and heat the crankcase half on an electric plate up to 150 °C. WARNING: Gently tap on crankcase half heated to 150 °C on a wood plate to make the bearings fall into their seats.

  • Page 78: Crankshaft Measurement

    ENGINE OVERHAUL CR 65 2012 Then make sure the lubrication hole (S) for the crankshaft ball bearing is free. Crankshaft measurement Always check the drive shaft axes misalignment when reusing the crankshaft. Max. drive shaft axes misalignment 0.05 mm Check the radial clearance to the connecting rod big end bearing.
  • Page 79 ENGINE OVERHAUL CR 65 2012 Water pump disassembly and check – Loosen the three screws and remove the water pump with its seal. – Remove the circlip (1) and slide the water pump impeller out of the shaft. – Push the water pump shaft (2) inside together with the ball bearings to remove it from the clutch cover.

  • Page 80: Piston Check

    ENGINE OVERHAUL CR 65 2012 Piston check Check what follows when reusing a piston: 1. Check for any dent or seizure on the piston sliding surface (you can use a fine grain abrasive stone to remove light seizure signs). 2. Piston ring groove: The piston ring must not get stuck in the groove. To clean the groove use an old piston ring or abrasive paper (grain 400).

  • Page 81: Reed Valve, Intake Flange

    ENGINE OVERHAUL CR 65 2012 WARNING: When replacing piston and cylinder make sure they have the same marking. The marking is on the piston crown and on the cylinder base. The table below indicates the tolerance limits for the relevant components.

  • Page 82: Gearbox Control Shaft Disassembly

    ENGINE OVERHAUL CR 65 2012 Gearbox control shaft disassembly – Fasten the gearbox control shaft in the vice (use protection jaws). – Remove the return spring (1) and loosen the spring holder (2) from the gearbox control shaft (6). – Remove the selector (4) together with the sliding plate (3) and the compres- sion spring (5) from the gearbox control shaft (6).

  • Page 83: Clutch - Check For Component Wear

    ENGINE OVERHAUL CR 65 2012 LOXEAL 86-54 LOCTITE 243 Clutch – check for component wear Check for component wear: Thrust bearing (1) Clutch springs (2) Minimum length 25 mm (when new 27 mm), if necessary replace all 6 springs. 6 lined plates (3) The lined plates must be flat and feature a minimum thickness of 1.80 mm.

  • Page 84: Kick Start Pedal Shaft Pre-Assembly

    ENGINE OVERHAUL CR 65 2012 Kick start pedal shaft pre-assembly – Fasten the shaft (4) of the kick start pedal with the lower grooved side in the vice (use protection jaws). – Insert the starting gear (5) with the stopping toothing down on the kick start pedal shaft.

  • Page 85: Input Shaft Assembly

    ENGINE OVERHAUL CR 65 2012 Input shaft assembly – Fasten the input shaft with the splined end down in the vice (use protection jaws). – Properly oil all components before assembly. – Insert the 5th neutral gear (1) with the front couplings upwards, and fit the circlip (2) with the sharp edge upwards.

  • Page 87: Engine Reassembly

    ENGINE REASSEMBLY CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 88 ENGINE REASSEMBLY CR 65 2012 Inserting the crankshaft in the engine casing ..........H.3 Refitting the gearbox shafts and the gearbox control ......... H.3 Crankcase halves coupling................H.4 Refitting the kick start pedal shaft ............... H.4 Refitting the selector plate and the gearbox control shaft ......H.5 Clutch assembly ..................

  • Page 89: Inserting The Crankshaft In The Engine Casing

    ENGINE REASSEMBLY CR 65 2012 Inserting the crankshaft in the engine casing – Fasten the right crankcase half onto the installation stand. – Grease the crankshaft oil seal and oil the crankshaft ball bearing. – Fit the crankshaft installation tool with the relevant bushing (1) and insert the crankshaft fully home.

  • Page 90: Refitting The Kick Start Pedal Shaft

    ENGINE REASSEMBLY CR 65 2012 Crankcase halves coupling – Remove the engine retainers on the installation stand. – Fit the two centring bushings in the right crankcase half. – Grease the oil seal of the input and output shafts. – The thrust washer 1 must not be fitted on the input shaft.

  • Page 91: Refitting The Selector Plate And The Gearbox Control Shaft

    ENGINE REASSEMBLY CR 65 2012 Refitting the selector plate and the gearbox control shaft – Place the selector spring (1) as shown in the engine casing picture. – Fit the selector lever (2) with the roller faced to the casing and the circlip (3) with the sharp edge upwards.

  • Page 92: Refitting The Primary Drive Sprocket

    ENGINE REASSEMBLY CR 65 2012 Refitting the primary drive sprocket WARNING: Before fitting the primary drive sprocket it is necessary to degrease the cone. – Degrease the crankshaft thread and smear some Loxeal 100 HSP. – Fit a new thrust washer and the hexagon nut.

  • Page 93: Refitting The Clutch Cover

    ENGINE REASSEMBLY CR 65 2012 Refitting the clutch cover – Make sure that both centring bushings are fitted in the engine casing. – Smear some grease on the casing sealing surface and fit a new clutch cover gasket. – Insert the thrust bearing 1 in the spring retaining plate.

  • Page 94: Refitting Reed Valve And Intake Flange

    ENGINE REASSEMBLY CR 65 2012 Refitting reed valve and intake flange – Insert the reed valve with a new gasket in the engine casing, fit the intake flange and fasten by means of 4 screws. – Fit the two remaining flanged screws on the cylinder base and tighten the 4 flanged screws to 18-20 Nm.

  • Page 95: Refitting The Ignition System And Adjusting The Fixed Spark Advance

    ENGINE REASSEMBLY CR 65 2012 Refitting the ignition system and adjusting the fixed spark advance – Smear some Loxeal 24-18 on the three socket head screws thread and fasten the stator (1) without tightening. – Smear some silicone in the cable ring and fit it in the relevant opening on the casing.

  • Page 96: Cylinder Head Installation

    ENGINE REASSEMBLY CR 65 2012 Cylinder head installation – Clean the cylinder and cylinder head sealing surfaces, and fit the O-rings (1) in the relevant grooves (in case smear with some grease). – Remove both centring bushings (2). – Position the cylinder head with the water fitting back (intake side).

  • Page 97: Gearbox Oil Filling Procedure

    ENGINE REASSEMBLY CR 65 2012 Gearbox oil filling procedure – Screw the gearbox breather pipe to the engine casing. – Screw the gearbox oil bleeding screw (1) with its new sealing ring, and tighten to 12 Nm. – Remove the oil filling screw from the clutch cover and fill in 0.50 l of gearbox oil.

  • Page 99: Front Suspension

    FRONT SUSPENSION CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 100 FRONT SUSPENSION CR 65 2012 Front suspension ..................I.3 Removing front fork ..................I.4 Fork spring features..................I.5 Fork oil ......................I.5 Cleaning the fork legs dust seals..............I.6 Workshop Manual Ed. 09-2011...

  • Page 101: Front Suspension

    FRONT SUSPENSION CR 65 2012 CR 65 Front suspension Upside-down hydraulic fork with advanced axle (compression and rebound damping adjustment) with ø 35 mm legs. The wheel travel on the forks axle is of 220 mm. Workshop Manual Ed. 09-2011...

  • Page 102: Removing Front Fork

    FRONT SUSPENSION CR 65 2012 Removing front fork 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: Release the front brake hose and the engine stop cable from the hose ring (1) inside the Number holder.

  • Page 103: Fork Spring Features

    FRONT SUSPENSION CR 65 2012 - Remove the brake calliper from the L.H. fork leg loosening the two retaining screws (2); Remove the front wheel as described in Section "Y"; Loosen the bolts (3) that secure the fork legs to steering head and bottom yoke;...

  • Page 104: Cleaning The Fork Legs Dust Seals

    FRONT SUSPENSION CR 65 2012 Cleaning the fork legs dust seals Position the bike on a stand to lift up the front wheel, and push down the dust seals protections on both fork legs. The dust seals protections remove dirt from the fork legs that builds up when using the vehicle, protecting the fork internal side.

  • Page 105: Rear Suspension

    REAR SUSPENSION CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 106 REAR SUSPENSION CR 65 2012 Rear shock absorber ..................J.3 Rear suspension....................J.3 Removing the rear shock absorber ...............J.4 Removing the chain rear casing ..............J.4 Disassembling and servicing the swinging arm ..........J.5 Servicing the swinging arm pivot ..............J.7 Servicing the rear rocker arm and suspension drop drag link .......J.7 Chain roller, chain guide, chain slider ............J.8...
  • Page 107 REAR SUSPENSION CR 65 2012 Rear shock absorber TIGHTENING TORQUE FIGURES 1 = 70 Nm/ 7.1 Kgm/ 51.63 ft/lb + Loctite 243 2 = 50 Nm/ 5.1 Kgm/ 36.88 ft/lb + Loctite 243 LUBRICATION POINTS (GREASE) Rear suspension The suspension of this motorcycle consists of a shock absorber, a series of linkages and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions.
  • Page 108 REAR SUSPENSION CR 65 2012 Rear shock absorber removal - Remove the front retaining pin (1) of the drag link (2) of the suspension on the chassis. - Remove the shock absorber lower retaining screw (3) and the upper one (4), and then slide the shock absorber (5) out.
  • Page 109 REAR SUSPENSION CR 65 2012 Disassembling and servicing the swinging arm - Set a stand 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 guide (A) on the swinging arm.
  • Page 110 REAR SUSPENSION CR 65 2012 - Remove the plug (1) of the shaft nut (2) locking the swinging arm onto the chassis. - After releasing the brake pedal (B) loosen the chassis retaining screw (4), using a 17 mm socket wrench on the left, and a 14 mm one on the right to remove the nut (2) of the swinging arm pivot (3) and the swinging arm (A) itself.
  • Page 111 REAR SUSPENSION CR 65 2012 Servicing the swinging arm pivot 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 112 REAR SUSPENSION CR 65 2012 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 113: Brakes

    BRAKES CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 114 BRAKES CR 65 2012 Braking system ..................... L.3 Brake disc ..................... L.4 Checking brake pads for wear / replacing the pads ........L.5 Pads removal....................L.5 Pads installation ................... L.5 Bleeding the front braking system ..............L.6 Bleeding the rear braking system ..............L.7 Changing the fluid..................

  • Page 115: Braking System

    BRAKES CR 65 2012 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 116: Brake Disc

    BRAKES CR 65 2012 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...

  • Page 117: Checking Brake Pads For Wear / Replacing The Pads

    BRAKES CR 65 2012 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 118: Bleeding The Front Braking System

    BRAKES CR 65 2012 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: - Take the rubber cover off the bleed valve (1).

  • Page 119: Bleeding The Rear Braking System

    BRAKES CR 65 2012 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: - Remove the protection cap and connect a clear hose to the bleed valve (1) of the calliper.

  • Page 120: Changing The Fluid

    BRAKES CR 65 2012 Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see page B.3) or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind.
  • Page 121 BRAKES CR 65 2012 - Remove the reservoir cover (2) or (2A) and the rubber gaiter. - Loosen the bleed valve on the calliper. - Pump the brake lever (3) or the brake pedal (3A) until draining all fluid. - Tighten the bleed valve and fill the reservoir with fresh fluid.

  • Page 123: Electrical System

    ELECTRICAL SYSTEM CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 124 ELECTRICAL SYSTEM CR 65 2012 Wiring diagram .................... M.3 Electrical components location ..............M.4 Spark plug ....................M.5 Handlebar switches ..................M.6 Left-hand switch ..................M.6 Ignition system resistance values - stator............ M.6 Ignition coil....................M.6 Ignition static parameters measurement with peak voltage adapter ... M.7 Important .....................

  • Page 125: Wiring Diagram

    ELECTRICAL SYSTEM CR 65 2012 Wiring diagram Stop button Pulsante di arresto Ignition coil Bobina di accensione Generator Generatore red-white blue-white red-black green-white red-green Cable colour bk : black bl : blue gn : green or : orange re : red...

  • Page 126: Electrical Components Location

    ELECTRICAL SYSTEM CR 65 2012 Electrical component location The ignition system includes the following elements: Generator (1), on the inner side of L.H. crankcase half cover; Electronic ignition coil (2) under the tank on the chassis right side; Electronic control unit (3) on steering tube rake, behind the Number holder;...

  • Page 127: Spark Plug

    ELECTRICAL SYSTEM CR 65 2012 Spark plug The spark plug (4) is a "NGK" BR8 ECM spark plug. 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.

  • Page 128: Handlebar Switches

    ELECTRICAL SYSTEM CR 65 2012 Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty. Left-hand switch 1 Engine stop switch (1) COLOUR Bl-Wh POSITION Ignition system resistance values - stator – Disconnect the stator plug and use a digital multimeter to measure the stator winding resistances at 20 °C.

  • Page 129: Ignition Static Parameters Measurement With Peak Voltage Adapter

    ELECTRICAL SYSTEM CR 65 2012 Ignition static parameter measurement with peak voltage adapter Measurement conditions: – cold engine – remove the number holder – loosen the spark plug, connect it and keep it to ground – all connector couplings and connections to ground must be free of corro- sion signs –...

  • Page 130: Important

    ELECTRICAL SYSTEM CR 65 2012 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;...

  • Page 131: Engine Cooling

    ENGINE COOLING CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 132 ENGINE COOLING CR 65 2012 Coolant level check ..................N.3 Cooling circuit ....................N.4 Engine cooling system overhaul ..............N.5 Workshop Manual Ed. 09-2011...
  • Page 133 ENGINE COOLING CR 65 2012 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 134 ENGINE COOLING CR 65 2012 Cooling circuit The forced circulation cooling system uses a centrifugal pump (located to the right of the cylinder head) and two downdraft radiators. Radiator cap Right-hand radiator Left-hand radiator Radiator to head pipe Water pump...
  • Page 135 ENGINE COOLING CR 65 2012 Servicing the engine cooling system 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 137: Hydraulically Controlled Clutch

    HYDRAULICALLY CONTROLLED CLUTCH CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 138 HYDRAULICALLY CONTROLLED CLUTCH CR 65 2012 Hydraulic clutch system .................P.3 Draining clutch fluid ..................P.4 Servicing the clutch master cylinder ..............P.4 Filling/draining the clutch hydraulic system ...........P.5 Workshop Manual Ed. 09-2011...
  • Page 139 HYDRAULICALLY CONTROLLED CLUTCH CR 65 2012 Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the right crankcase half. The clutch is disengaged by the piston (5) that operates the pressure plate (4). Drive is transmitted from the crankshaft to the gearbox input shaft via the gear on the clutch housing (8).
  • Page 140 HYDRAULICALLY CONTROLLED CLUTCH CR 65 2012 Draining clutch fluid Connect a plastic hose to the bleed valve and loosen the valve turning it back by 1 or 2 turns. Remove reservoir cap and bellow diaphragm and operate the control lever until draining all fluid.
  • Page 141 HYDRAULICALLY CONTROLLED CLUTCH CR 65 2012 Filling/draining the clutch hydraulic system Proceed as follows: - Remove screws (1), cover (2) and rubber diaphragm (4); - Remove the rubber cap (3) and loosen the bleed valve (5); - Connect the bleed valve to a pipe, and use a syringe (6) to fill in the fluid (of the type specified in the LUBRICANT TABLE at page A.9) until topping-up the...

  • Page 143: Fuel Supply

    FUEL SUPPLY CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 144 FUEL SUPPLY CR 65 2012 Carburettor setting ..................S.3 Original setting....................S.3 Main information about carburettor wear ............S.3 Idle rpm – A, Idle adjustment ................ S.4 Valve opening – B ..................S.4 Partial load – C ..................... S.4 Full load – D ....................S.4 Carburettor drawing ..................
  • Page 145 FUEL SUPPLY CR 65 2012 Carburettor setting Original setting The carburettor original settings are: 500 m altitude above sea level, temperature of nearly 20 °C, main use off-road and possibility of using premium grade fuel in Central Europe (RON 95, without lead), mixed with 2T oil. Oil-fuel mixture ratio at 3% during running-in phase, at 2% after running-in.
  • Page 146 FUEL SUPPLY CR 65 2012 Idle rpm – A, Idle adjustment Operation with closed throttle valve. This rpm is controlled by the position of the air adjuster screw (1) and the throttle valve stop screw (2). Any adjustment shall be carried out with warm engine only.
  • Page 147 FUEL SUPPLY CR 65 2012 CArBurettOr DrAWInG 1 Air adjusting screw 8 Maximum jet 2 Throttle valve spring 9 Minimum jet 3 Air adjuster spring 11 Cold kick start lever 4 Throttle valve 13 Floater bowl 5 Needle valve 14 Floater + pin...
  • Page 148 FUEL SUPPLY CR 65 2012 Removing and refitting the carburettor WARNING: before acting on the carburettor, thoroughly clean the motorcycle. – Close the fuel cock (1) and remove the pipe (2) from the carburettor. – Remove the clamp (3) and release the carburettor breather pipes from the transmission oil breather pipe.
  • Page 149 FUEL SUPPLY CR 65 2012 – Loosen the clamp (6) on the filter box connection unions. – Remove saddle and side panels as described in Section "E". – Disconnect the silencer from the rear chassis supporting plate. – Remove the two lower screws (7) and loosen the two upper screws (8) that connect the rear chassis to the front chassis.
  • Page 150 FUEL SUPPLY CR 65 2012 Disassembling the carburettor WARNING: Before starting disassembling the carburettor, prepare and clean the working area. Such area should be sufficiently big to arrange in an orderly way all carburettor single components. – Disconnect all carburettor breather pipes.
  • Page 151 FUEL SUPPLY CR 65 2012 – Remove the idle adjusting screw (8) together with the spring. – Screw the air adjuster screw (1) fully home counting and recording the turns. – Remove the air adjuster screw, the spring, the washer and the O-ring.
  • Page 152 FUEL SUPPLY CR 65 2012 Checking the taper needle and throttle valve – Check that the taper needle (3) is not worn out or deformed. Because of the engine vibrations the throttle valve, the floater taper needle, and the main nozzle are subject to high wear. Wear causes carburettor malfunc- tions (for example too rich mixture).
  • Page 153 FUEL SUPPLY CR 65 2012 Emptying the carburettor bowl – Close the fuel cock and place a cloth under the carburettor able to absorb fuel flowing out. – Open the closure screw 1, have the residual fuel flowing into the bowl, and clean the closure screw with compressed air.

  • Page 155: Special Tools

    SPECIAL TOOLS CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 156 SPECIAL TOOLS CR 65 2012 SPECIAL TOOLS HUSQVARNA CODE DESCRIPTION 1 8000 H7677 Crankshaft removing tool 2 Commercial Bearing puller 3 Commercial Insert for bearing puller 12 - 16 mm 4 8000 H7678 Primary gear retainer 5 Commercial Flywheel and clutch retainer...

  • Page 157: Tightening Torque Figures

    TIGHTENING TORQUE FIGURES CR 65 2012 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. 09-2011...
  • Page 158 TIGHTENING TORQUE FIGURES CR 65 2012 CHASSIS NOMINAL DESCRIPTION MEASURE TORQUE NOTES (Nm) Chain roller to chassis retaining screw LOCTITE 243 Front low. and upp. engine retaining screw LOCTITE 243 Engine lock nut LOCTITE 243 Rear chassis to chassis connecting screw Stand support upper retaining screw...
  • Page 159 TIGHTENING TORQUE FIGURES CR 65 2012 REAR SUSPENSION NOMINAL DESCRIPTION MEASURE TORQUE NOTES (Nm) Chain slider on fork retaining screw Rear chain guide retainers Shock absorber to chassis retaining screw LOCTITE 243 Shock absorber to rocker arm retaining screw LOCTITE 243 Shock absorber low. and upp. lock nut LOCTITE 243 Drag link to chassis connecting screw Drag link to rocker arm connecting screw Rocker arm to swinging arm connecting screw Rocker arm screws retaining nut LOCTITE 243 Swinging arm pivot retaining nut LOCTITE 243 Rear brake hose ring retaining self-threading screw MUDGUARD FAIRINGS NOMINAL DESCRIPTION MEASURE TORQUE NOTES...
  • Page 160 TIGHTENING TORQUE FIGURES CR 65 2012 SUPPLY SYSTEM NOMINAL DESCRIPTION MEASURE TORQUE NOTES (Nm) Tank front retaining screw Cock retaining self-threading screw WHEELS AND BRAKES NOMINAL DESCRIPTION MEASURE TORQUE NOTES (Nm) Front brake disc retaining screw LOCTITE 243 Front wheel axle retaining screw Front wheel axle to fork retaining screw Rear brake disc retaining screw LOCTITE 243 Sprocket retaining nut Rear wheel axle Rear wheel retaining nut...
  • Page 161 TIGHTENING TORQUE FIGURES CR 65 2012 COOLING SYSTEM NOMINAL DESCRIPTION MEASURE TORQUE NOTES (Nm) Radiator retaining screw Radiator retaining flanged lock nut 1 Nm = 0.73756 ft/lb NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows M5x0.8 5.6-6.2 Nm 0.57-0.63 Kgm 4.1-4.5 ft/lb M6x1 7.6-8.4 Nm 0.80-0.85 Kgm 5.8-6.1 ft/lb M8x1.25 24-26 Nm 2.4-2.6 Kgm 17.3-18.8 ft/lb ENGINE (+/- 5%) Primary drive sprocket hexagon nut ....M14x1.25 (+Loxeal 100 HSP) 70 Nm 7.14 Kgm...
  • Page 162 TIGHTENING TORQUE FIGURES CR 65 2012 INSTALLATION TOLERANCES AND CLEARANCES Crankshaft ..............max. drive shaft axes misalignment 0.050 mm Handwheel external measure ........57 mm +/- 0.05 mm Connecting rod big end bearing .........max. radial clearance 0.030 mm Max. piston pin ............radial clearance 0.03 mm...

  • Page 163: Chassis And Wheels

    CHASSIS AND WHEELS CR 65 2012 Section Workshop Manual Ed. 09-2011...
  • Page 164 CHASSIS AND WHEELS CR 65 2012 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 ..................

  • Page 165: Chassis

    CHASSIS AND WHEELS CR 65 2012 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 166: Front Wheel

    CHASSIS AND WHEELS CR 65 2012 Front wheel Light alloy wheel hub and rim with high-strength steel spokes. Make, type and size of light alloy wheel rims: 1.6x14” Make, type and size of tyre........"Pirelli" Scorpion ................MX 60/100 14" 29M NHS Cold tyre pressure ..........0.8 Bar...
  • Page 167 CHASSIS AND WHEELS CR 65 2012 Removing the front wheel Set a stand under the engine and see that the front wheel is lifted from the ground. Loosen the screw (1) placed on the left side; Loosen the two screws (2) that fasten the pin head to the fork bottom on the right side;...
  • Page 168 CHASSIS AND WHEELS CR 65 2012 Reassembling the front wheel Fit the wheel between the fork legs so as to set the brake disc into the calliper. Working on right side, push the previously-greased wheel axle (3) all the way down, tapping it on left fork leg;...

  • Page 169: Rear Wheel

    CHASSIS AND WHEELS CR 65 2012 Rear wheel Light alloy wheel hub and rim with high-strength steel spokes. Make, type and size of light alloy wheel rim: 1.6x12”; Make, type and size of tyre......"Pirelli" Scorpion; MX 12" 50M NHS Cold tyre pressure ..........
  • Page 170 CHASSIS AND WHEELS CR 65 2012 Removing the rear wheel Set a stand 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 171: Wheel Servicing

    CHASSIS AND WHEELS CR 65 2012 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 172: Wheel Spokes

    CHASSIS AND WHEELS CR 65 2012 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 173: Rear Chain Sprocket, Secondary Drive Sprocket And Chain

    CHASSIS AND WHEELS CR 65 2012 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 five screws that retain it to the hub.
  • Page 174 CHASSIS AND WHEELS CR 65 2012 Checking sprocket 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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