Repair Manual Husqvarna CR 65 2012

CR 65 2012

Workshop Manual Ed. 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.1st Edition (09-2011)

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CR 65 2012

H02017

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CR 65 : ZKHCR6530CV000001


FOREWORD, TABLE OF CONTENTS

1st Edition (09-2011)Printed in Italy

MODELS COVERED (from serial number onwards)

Copyright byHUSQVARNA MOTORCYCLES S.R.L.BMW GroupTechnical ServiceVia Nino Bixio, 821024(Varese) - Italytel. ++39 0332 75.61.11tel. ++39 0332 756 558www.husqvarna-motorcycles.com

Workshop Manual

1. Chassis serial number

CR 65 / 2012

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CR 65 2012



ForewordThis 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.For ease of understanding, diagrams and photographs are provided next to the text.Notes with special significance are identified as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from non-compliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tipsTo prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations: before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify

problem symptoms; diagnose the problem and identify the causes clearly. This manual provides basic background information that must

be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular periods;

plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays; avoid unnecessary disassembly work to get to the part that needs repairing. Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

Recommended shop practices1 Always replace gaskets, sealing rings and split pins with new ones.2 When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the speci-

fied torque and follow a cross pattern.3 Always mark any parts or positions that might be confused upon assembly.4 Use genuine HUSQVARNA parts and the recommended lubricant brands.5 Use special tools where specified.6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

IMPORTANT: Where not specified, reassembled components must be tightened to the proper torque as indicated in the tables provided in section "X".

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Table of ContentsTitle SectionForeword, Table of Contents ............................................................................... aImportant Notices ................................................................................................ bGeneral Information .............................................................................................AMaintenance ........................................................................................................BTroubleshooting .................................................................................................. CSettings and Adjustments ................................................................................... DGeneral Procedures ............................................................................................EEngine Disassembly ............................................................................................FEngine Overhaul ................................................................................................. GEngine Reassembly............................................................................................ HFront Suspension ................................................................................................. IRear Suspension ................................................................................................. JBrakes ................................................................................................................. LElectrical System ................................................................................................MEngine Cooling ................................................................................................... NHydraulically Controlled Clutch............................................................................PFuel supply ..........................................................................................................SSpecial Tools ......................................................................................................WTightening Torque Figures ...................................................................................XChassis and Wheels ............................................................................................Y

NOTES

Unless otherwise specified, data and specifications apply to all models.

b.1

CR 65 2012

b


IMPORTANT NOTICES

Section

b.2

CR 65 2012

IMPORTANT NOTICES


1) CR models are RACING motorcycles and are guaranteed to be free from operating defects; a scheduled maintenance chart for racing use is provided in Section B.

* In order to maintain the vehicles 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. In case of motorcycle hire the warranty becomes NULL and VOID.

NotesLeft and right side is determined when seated on motorcycle.

Z: number of teeth

A: AustriaAUS: AustraliaB: BelgiumBR: BrazilCDN: CanadaCH: SwitzerlandD: GermanyE: SpainF: FranceFIN: FinlandGB: Great BritainI: ItalyJ: JapanUSA: United States of America

Unless otherwise specified, data and instructions apply to all market variants.

A.1

CR 65 2012

A


GENERAL INFORMATION

Section

A.2

CR 65 2012

GENERAL INFORMATION


Engine ..........................................................................................................A.3Fuel system ..................................................................................................A.3Lubrication ....................................................................................................A.3Cooling .........................................................................................................A.3Ignition system..............................................................................................A.3Kick ..............................................................................................................A.3Primary drive ................................................................................................A.3Gearbox ........................................................................................................A.3Secondary drive............................................................................................A.3Drive chain....................................................................................................A.3Chassis .........................................................................................................A.3Suspension ...................................................................................................A.3Brakes ..........................................................................................................A.4Wheels..........................................................................................................A.4Tyres .............................................................................................................A.4Overall dimensions - Weight .........................................................................A.4Electrical components location .....................................................................A.5Capacities .....................................................................................................A.5

A.3

CR 65 2012


GENERAL INFORMATION

EngineSingle cylinder, 2 strokeBore .........................................................................................................45 mmStroke ...................................................................................................40.8 mmDisplacement .................................................................................. 64.89 cu.cmCompression ratio ......................................................................................9.1:1

Fuel systemCarburettor type MIKUNI.........TM24Maximum jet .................................................................................................240Minimum jet ....................................................................................................40

LubricationEngine .............................................. fuel-oil mixture at 3% during running-in, at 2% after running-in.Primary drive/gearbox with oil inside the crankcase

CoolingLiquid-cooling with double radiator

Ignition systemSpark plug type..........................................................................NGK BR8 ECMSpark plug electrode gap........................................................................0.6 mm

Kick .............................................................................................................start

Primary driveDrive pinion gear ........................................................................................ Z 23Sprocket .................................................................................................... Z 75Transmission ratio ......................................................................................3.26

GearboxType ............................................................................ constant mesh gear typeTransmission ratio1st gear...................................................................................... 2.846 (z 37/13)2nd gear .................................................................................... 2.125 (z 34/16)3rd gear ..................................................................................... 1.722 (z 31/18)4th gear ..................................................................................... 1.428 (z 30/21)5th gear ..................................................................................... 1.217 (z 28/23)6th gear ..................................................................................... 1.083 (z 26/24)

Secondary driveTransmission sprocket ............................................................................... Z 14Rear sprocket ............................................................................................. Z 48Transmission ratio ......................................................................................3.43

Drive chainMake and type ..............................................................D.I.D. 420 - 1/2 x 1/4

ChassisType single frame, in steel tubes with rectangular and oval section; rear chassis in squared sectioned tubes in light alloy.

SuspensionFrontType ........................................upside-down telescopic fork with advanced axle (damping rebound and compression adjustment); Tubes ................................................................................................... 35 mmWheel travel...........................................................................................220 mm

RearType .................................... progressive Soft Damp with hydraulic monoshock(spring preload, rebound and compression damping adjustment)Wheel travel...........................................................................................270 mm

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CR 65 2012

1130 mm (44.49 inch)

1640 mm (64.57 inch)

230 mm (9.06 inch)243 mm (9.57 inch)

750

mm

(29,

53 in

ch)

280

mm

(11.

02 in

ch)

1015

mm

(39.

96 in

ch)

*770 mm (30.31 inch)

GENERAL INFORMATION


BrakesFrontType ....................................................... with fixed disc Wave type 200 mmhydraulic control and four piston fixed calliper.

RearType ....................................................... with fixed disc Wave type 165 mmwith hydraulic control and two piston fixed calliper.

WheelsRimsFront .................................................................................. in light alloy: 1.6x14Rear ................................................................................... in light alloy: 1.6x12

TyresFront ........................................ PIRELLI SCORPION MX60/100 14 29M NHSRear ..........................................PIRELLI SCORPION MX80/100 12 50M NHS

Cold tyre pressureFront ....................................................................................................... 0.8 barRear ........................................................................................................ 0.8 bar

Overall dimensions - Weight

Kerb weight, without fuel ........................................................ 56.8 kg (125.2 lb)*: max. widthTrail ............................................................................................65 mm (2.56 in)Steering tube rake ......................................................................................25.6

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CR 65 2012


GENERAL INFORMATION

Electrical component locationThe 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 QuantityFuel tank oil-fuel mixture at 3% for running-in, then at 2% 3.5 litres Oil for mixture CASTROL XR77 Crankcase oil CASTROL POWER RACING 10W-50 500 cc (oil change)

Front fork oil CASTROL SYNTHETIC FORK OIL - 5W

Cooling system fluid CASTROL MOTORCYCLE COOLANT 0.6 litresFront brake fluid CASTROL RESPONSE SUPER (DOT 4)Rear brake fluid CASTROL RESPONSE SUPER (DOT 4)Clutch fluid MINERAL OIL SAE 10 FOR HYDRAULIC CIRCUITSDrive chain lubrication CASTROL CHAIN LUBE RACINGGrease lubrication CASTROL LM GREASE 2Electric contact protection CASTROL METAL PARTS CLEANERFillers for radiator AREXONS LIQUID FILLER Air filter oil CASTROL Foam air filter oilAir filter cleaner CASTROL Foam air filter cleaner

IMPORTANT - Do not add any additives to fuel or lubricants

B.1

CR 65 2012

B


MAINTENANCE

Section

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CR 65 2012

MAINTENANCE


ENGINE

Afte

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fir

st 5

hou

rs

Ever

y 20

ho

urs

Ever

y 40

ho

urs

Onc

e a

year

Bef

ore

the

race

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

Idle adjustment (warm engine)

Breather pipes conditions and position (without bends) check

Reed valve reed check

Clutch plates wear check

Clutch hub screw tightening check

Clutch spring length check

Cooling system leakage check

Cylinder and piston wear check

Drive shaft axes misalignment check

Connecting rod big end bearing radial clearance check

Connecting rod small end bearing radial clearance check

Main bearing wear check

Crankshaft and connecting rod big end bearing replacement

Gearbox wear check (selector drum and bearings included)

Carburettor cleaning and adjustment

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CR 65 2012


MAINTENANCE

CHASSIS

Afte

r the

fir

st 5

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Ever

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urs

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Bef

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race

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 * Brake level, pad thickness, brake disc check

Brake pipe status check

Front lever and brake pedal adjustment and operation check

Braking system screw tightening check

Exhaust system check

Control cable lubrication and free sliding check

Air filter and filter box cleaning

Shock absorber and fork operation check

Swinging arm support check

Steering bearing check and/or adjustment

Screw tightening check

Fork dust seal removal and cleaning

Rim runout and spoke tension check

Tyre pressure and condition check

Chain, master link, sprockets wear check

Chain lubrication

Wheel bearing clearance check

* Operations and actions to be carried out according to the use conditions.

B.4

CR 65 2012

MAINTENANCE


CHECKS

Bef

ore

ever

yus

e

Afte

r eve

rycl

eani

ng

Befo

re e

very

ra

ce

Onc

ea

year

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

Air filter and filter box cleaning

Tyre pressure and wear check

Screw, nut and tie correct tightening check

Fuel pipe status check

C.1

CR 65 2012

C


TROUBLESHOOTING

Section

C.2

CR 65 2012

TROUBLESHOOTING


ENGINE

Trouble Cause Remedy

Engine does not start or Insufficient compressionit 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. Cylinder head loosely tightened Tighten 6. Head gasket leaking Replace 7. Spark plug loose Tighten Weak or no spark 1. Spark plug faulty Replace 2. Fouled or wet spark plug Clean or dry 3. Spark plug electrode gap too wide Adjust 4. Ignition coil faulty Replace 5. High-tension cables open circuit or shorted Check

The carburettor is not receiving fuel 1. Tank cap breather clogged Clean 2. Fuel cock clogged Clean 3. Fuel feed pipe clogged Clean 4. Floatervalveorfloatersfaulty Replace 5. Linkageisblockingfloatervalve Release

Carburettor floods 1. High fuel level in bowl Adjust 2. Floatervalveorfloaterswornorstuck open Replace or release

The engine stops 1. Dirty spark plug Cleaneasily 2. Carburettor jets clogged Clean 3. Low idle Adjust

Engine is noisy Noise seems to come from piston 1. Too much piston-to-cylinder clearance Replace 2. Worn piston rings or piston grooves Replace 3. Too much carbon build-up in combustion chamber or on piston crown Clean

Noise seems to come from crankshaft 1. Worn main bearings Replace 2. Connecting rod big end has too much side clearanceorendfloat Replace 3. Crankshaft gear damaged Replace 4. Crankshaft locknut loose Tighten

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CR 65 2012


TROUBLESHOOTING


The noise seems to come 1. Chain stretched or incorrectly adjusted Replace or adjustfrom the secondary 2. Worn transmission sprockets Replacetransmission chain

The clutch slides 1. Weak clutch springs Replace 2. Worn clutch plates Replace

The clutch is tight 1. Non uniform spring load Replace 2. Bent clutch plates Replace

The gears cannot be inserted 1. Bent or seized gearbox forks Replace 2. Worn gear ratchets Replace 3. Damaged shifter fork shafts Replace

Gear shift pedal does not return in position 1. Weak or broken selector return spring Replace 2. Worn shifter forks Replace

The gears are disengaged 1. Worn sliding gear engagements Replace 2. Worn gear grooves Replace 3. Worn dog slots in gears Replace 4. Worn selector shaft splines Replace 5. Damaged shifter fork shafts Replace

Engine power lack 1. Dirtyairfilter Clean 2. Carburettor main jet clogged or Wrong size Clean or replace 3. Poor fuel quality Replace 4. Intake coupling loose Tighten 5. Spark plug electrode gap too wide Adjust 6. Insufficientcompression Identifycause

The engine overheats 1. Dirty combustion chamber and/or piston crown with carbon deposits Clean 2. Insufficientoilincrankcaseoruseof wrong oil Top up or change 3. Obstructionsblockingairflowonradiator Clean 4. Cylinder head gasket leaking Replace 5. Clutch slips Adjust

C.4

CR 65 2012

TROUBLESHOOTING


CHASSIS

Trouble Cause RemedyThe handlebar is hard to turn 1. Tyrepressureinsufficient 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

The handlebar vibrates 1. Bent fork legs Replace 2. Bent front wheel axle Replace 3. Bent/broken chassis Replace 4. Bent front wheel rim Replace 5. Worn front wheel bearings Replace

Shock absorption is 1. Exceeding oil quantity in fork legs Drain the exceeding oiltoo hard 2. Fork oil viscosity too high Change 3. Overinflatedtyres Deflate 4. Improperly set rear shock absorber Adjust

Shock absorption is 1. Insufficientoilquantityinforklegs Topuptoo soft 2. Fork oil viscosity too low Change 3. Weak fork springs Replace 4. Weak rear shock absorber spring Replace 5. Improperly set rear shock absorber Adjust

Wheel (front and 1. Bent wheel rim Replacerear) vibrates 2. Worn wheel hub bearings Replace 3. Incorrect spoke tension Adjust 4. Wheel axle nut loose Tighten 5. Worn rear swinging arm bearings Replace 6. Improperly adjusted chain tensioners Adjust 7. Improperly balanced wheel Balance

Rear suspension is 1. Shock absorber worn ball joints Replacenoisy 2. Faulty shock absorber Replace

Insufficient braking 1. Air presence in braking system circuit Bleed(front and rear) 2. Insufficientfluidintank Topup 3. Worn brake pad and/or disc Replace 4. Damaged disc Replace 5. Improperly adjusted brake pedal Adjust 6. Waterinbrakesystem Changefluid

C.5

CR 65 2012


TROUBLESHOOTING

ELECTRICAL SYSTEM (see also Section M)


The spark plug gets dirty 1. Mixture too rich Adjust carburettoreasily 2. Dirtyairfilter Clean 3. Worn piston rings Replace 4. Worn piston or cylinder liner Replace 5. Spark plug featuring a too high heat rating Replace with recommended

spark plug

Spark plug electrodes 1. Mixture too lean Adjust carburettoroverheat 2. Spark plug electrode gap too close Adjust 3. Spark plug featuring a too low heat rating Replace with recommended

spark plug

D.1

CR 65 2012

D


SETTINGS AND ADJUSTMENTS

Section

D.2

CR 65 2012



Saddle removal.............................................................................................D.4Tank removal ................................................................................................D.4Remove the chain/sprocket cover protection casing ....................................D.5Throttle cable adjustment .............................................................................D.5Carburettor adjustment .................................................................................D.6Idle adjustment .............................................................................................D.6Front brake fluid level check ........................................................................D.6Clutch oil level check ....................................................................................D.7Front brake lever adjustment ........................................................................D.8Lever distance adjustment............................................................................D.8Clutch distance adjustment ..........................................................................D.8Rear brake pedal position adjustment .........................................................D.9Rear brake pedal free play adjustment ........................................................D.9Rear brake fluid level check .......................................................................D.10Oil level check ............................................................................................D.11Oil replacement ..........................................................................................D.11Coolant level check ....................................................................................D.12Coolant replacement ..................................................................................D.12Air filter cleaning and check .......................................................................D.13Chain adjustment .......................................................................................D.14Chain lubrication .........................................................................................D.14Removal and cleaning ................................................................................D.14Chain cleaning ............................................................................................D.14Chain lubrication .........................................................................................D.14Fork adjustment .........................................................................................D.15Rebound damping adjustment (RH fork leg) ..............................................D.15Compression damping adjustment (LH fork leg) ........................................D.15Fork position adjustment ............................................................................D.16Rear shock absorber adjustment................................................................D.16Shock absorber spring preload adjustment ................................................D.17Shock absorber hydraulic damping adjustment..........................................D.18Steering bearing clearance adjustment ......................................................D.19Handlebar position change .........................................................................D.19Tank supply and breather pipe check .........................................................D.21Exhaust system check ................................................................................D.21Sound deadening material replacement .....................................................D.22

D.3

CR 65 2012



CR 65

D.4

CR 65 2012

1

2

2

3 4

7

8



Saddle removalTurn the rear pin (1) counterclockwise.Release the saddle (2) from the front retaining screw pin.

Tank removalRemove 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. Detach hose (4) from carburettor making sure to drain any fuel in the hose into a container.

Remove the side panels as described in section E.

Slide the breather hose (7) out of the steering tube.Remove the retaining screw (8) and then the tank (9).

D.5

CR 65 2012

3

4 1

2

2

1

4

3

9

2 mm



Remove the chain/sprocket cover protection casingCut 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.

Throttle cable adjustmentTo check the correct adjustment of the throttle control cable, operate as fol-lows:- Turn throttle control twistgrip (1) and make sure it has about 2 mm free

play;

- If not so, move the rubber protection (2), loosen the ring nut (3) and work the adjuster screw (4) (loosen to decrease play or tighten to increase it);

- After the adjustment lock the ring nut (3) and fit the rubber protection (2) again.

After the adjustment, check for no rpm increase when turning the han-dlebar to the left and to the right with engine running at idle; if this is the case, carry out the adjustment again.

Operation with damaged throttle cable could result in an unsafe riding condition.

Exhaust gas contains poisonous carbon monoxide. Never run the engine indoors.

D.6

CR 65 2012

1

2

3

1

2



Carburettor adjustmentAdjust 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).

- Turn the adjuster screw (2) clockwise to fully closed position, and then turn it back by 3 turns.

- Gradually loosen the screw (1) until achieving suitable idle speed setting.

Idle adjustmentAdjust 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 as required (turn clockwise to increase the speed and counter clockwise to reduce it).

Front brake fluid level check Check the front brake fluid level as follows:

- Stand the vehicle level and upright;

- Turn the handlebar so that the front brake master cylinder is in horizontal position;

- Loosen the screws (1) and remove cover (2) together with diaphragm (3);

- Make sure the oil level is about 3 mm from the top edge, in case top-up with oil of the type specified in the "LUBRICATION AND SUPPLIES" table.

D.7

CR 65 2012

3 mm

1

2

3



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").

Too much brake lever free play may reduce braking action: CHECK BRAKE PAD THICKNESS (see Section "L").

Do not pour brake fluid on painted surfaces.

Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand.

Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and contact a doctor if your eyes were exposed.

Clutch fluid level check Check the clutch fluid level as follows:

- Stand the minicross level and upright;

- Loosen the screws (1) and remove cover (2) together with diaphragm (3); - Make sure the oil level is about 3 mm from the top edge, in case top-up with

oil of the type specified in the "LUBRICATION AND SUPPLIES" table.

If the clutch feels mushy when pulled, there may be air in the brake line or the brake may be defective: CHECK CLUTCH HYDRAULIC SYSTEM.

Do not spill brake fluid onto any painted surface or lens (for example lights lens).


Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and contact a doctor if your eyes were exposed.

D.8

CR 65 2012

1

2

3 A

B

B

A

45



Front brake lever adjustment

POSITION ADjUSTMENTLoosen the screws (2) to adjust the lever (1) position.When finished, tighten the screws (2) again.

Lever distance adjustmentTo adjust the distance between the lever (1) and the throttle twistgrip work on the ring nut (3) by turning it clockwise "A" to decrease it, and counterclockwise "B" to increase it.

Clutch lever adjustment

LEvER DISTANCE ADjUSTMENTTo adjust the distance between the clutch lever (1) and the throttle twistgrip work on knob (3) by turning it clockwise "A" to increase it, and counterclockwise "B" to decrease it.

D.9

CR 65 2012

A

2

1

3

5 mm0.2 in.

B

3

4

5



Rear brake pedal position adjustmentThe 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);- When finished, tighten the screw (1).Once this adjustment is completed, adjust the free play of the pedal following the instructions provided in paragraph "Rear brake pedal free play adjustment".

Rear brake pedal free play adjustmentThe 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);- operate the pump rod (5) to increase or decrease the free play;- tighten nut (4) at the end of the operation.

When the free play requirement is not met, the brake pads will be subjected to an early wear that may lead to TOTAL BRAKE INEFFECTIvENESS.

If the brake pedal 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).

D.10

CR 65 2012

MIN1

3

2



Rear brake fluid level checkThe 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" table.

A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.

If the brake pedal 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").

Too much brake lever free play may reduce braking action: CHECK BRAKE PAD THICKNESS (see Section "L").

Do not spill brake fluid onto any painted surface or lens (for example lights lens).


Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed.

D.11

CR 65 2012

1

2

3



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.- Check the oil level is above the inspection window (1) lower edge.

If the oil level is low, top-up through the dedicated oil hole (2) located on the casing upper side.

Oil replacement

Be careful not to touch hot engine oil.

Drain the oil with WARM ENGINE; proceed as follows:- Remove the oil filler cap (2).- Put a drip pan under engine.- Remove oil drainage plug (3).- Evacuate the exhausted oil.- Refit the drainage plug (3) (15 Nm / 1.5 Kgm / 11.06 ft/lb).- Top-up with suitable quantity through the dedicated oil hole (2).

Make sure the oil level is conforming to what stated in the relevant paragraph.

D.12

CR 65 2012

1

2

BB

AA



Coolant level checkCheck 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.The radiator cap features two locking positions: the first one is for prior discharge of pressure from the cooling system.

Avoid removing radiator cap when engine is hot, as coolant may spout out and cause scalding.

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

Coolant replacementPlace a vessel on the RH side of the cylinder, under the screw (1).

SLOWLY open the RH radiator cap (2); slope the motorcycle on the left side to drain the coolant easily in the vessel.Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any possible air bubbles.

Periodically check the connecting hoses (see Scheduled Maintenance Chart): this will avoid coolant leakage and consequent engine seizure. 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).

D.13

CR 65 2012

2

1

3

4

4

5



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).

- Clean the filter (4) with suitable products, then soak it in the specific oil.- Use a cloth to clean the filter box internal side (5).- Reassemble all parts, in the reverse order compared to disassembly.

Never tamper the filter box cover: we strongly recommend not to remove the material delimited by the cut to increase the air flow because this would lead to a drastic decrease of performances at low and medium rpm, against a very little improvement at high rpm; furthermore the cover protects the filter against water, mud and dirt.

We recommend keeping a spare filter.

D.14

CR 65 2012

1

4

3

2

2

3

4

A



Chain adjustment Chain should be checked, adjusted and lubricated as per the "Maintenance Chart" (see Section B). to ensure safety and prevent excessive wear. If the chain becomes badly worn or is poorly adjusted (i.e., if input and output shafts loose or too taut), it could escape from sprocket or break. Remove the chain protection casings as indicated in the relevant paragraph.

Place the minicross on a stand and insert a 25 mm drill rod (A) on the upper chain guide.Adjust the chain tension so that the drill rod passes freely without excessively loosening the chain.

If it is not, proceed as follows:- Loosen the hexagon nut (1).- Loosen the check nuts (2) on both sides.- Work on screw (3) on rear swinging arm both sides, to increase or decrease

the chain tension having care to centre the wheel in the rear swinging arm referring to the notches on the swinging arm.

- When the desired tension is reached block the rear wheel shaft (4) by tighten-ing the hexagon nut (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.

D.15

CR 65 2012

21

3



Chain lubricationLubricate 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 cleaningWhen particularly dirty, remove and clean the chain before lubrication. Proceed as follows:- Set a stand or a block under the engine and see that the rear wheel is lifted

from the ground.- Remove the chain protection casings as indicated in the relevant paragraph.- Remove clip (1), master link (2) and the chain (3). To reassemble, reverse

the above procedure.Make sure that the chain is neither worn out nor damaged. If the rollers or the links are damaged, replace the chain by following the instructions given in the Scheduled Maintenance Chart. Ensure that the sprockets are not damaged. Wash and clean the chain as described hereunder.

Chain cleaningWash using petroleum or naphtha. If you use fuel or especially trichloroethylene, dry and lubricate the chain to avoid oxidisation.

Chain lubrication After drying, dip the chain in Molybdenum Disulphide chain lubricant, if possible, or in warm high-viscosity engine oil (if warmed up, oil will be more fluid).

Fork adjustmentThe fork RH and LH legs can be adjusted both in compression (RH fork leg) and rebound (LH fork leg) damping, respectively. To adjust the fork proceed as follows.

Rebound damping adjustment (RH fork leg)To adjust start always from the standard position by rotating clockwise until end of stroke and then counterclockwise by 101 CLICKS. Turn clockwise to increase the damping and vice versa.

Compression damping adjustment (LH fork leg)To adjust start always from the standard position by rotating clockwise until end of stroke and then counterclockwise by 101 CLICKS. Turn clockwise to increase the damping and vice versa.

Rebound damping (RH leg)Standard 10 clicks counterclockwise from end of travelCompression damping (LH leg)Standard 10 clicks counterclockwise from end of travel

D.16

CR 65 2012

CA

B

D

A

B

C

1

2



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.Align the steering head upper part with one of the four notches (A, B, C and D) as shown in the figure.To keep the desired position tighten first the screw (2) and then the screws (1) fully home.Repeat the operation on the other leg.

Carry out the same fork position adjustment procedure on both legs.

Shock absorber adjustmentThe rear shock absorber must be adjusted according to the rider weight and the road conditions. IT is possible to adjust the shock absorber acting on the spring pre-load according to the rider weight.

The shock absorber adjustment affects both the stability and the handling of the motorcycle. After changing the standard suspension setting, ride with care. Before making any change, we recommend to identify a reference dimension"A" with bike on the central stand and front wheel raised off the ground.

- Have the bike resting on ground without rider. Measure dimension "A". The difference between dimension "A" with the wheel raised off the ground

and dimension "A" with the wheel on the ground shall be 2530 mm (0.98 1.18 in).

- Have bike resting on the ground with rider sitting on it; Measure dimension "A"; The difference between dimension "A" with the wheel raised off the ground

and rider sitting on it shall be 6070 mm (2.36 2.76 in).

B: silencer retaining screw axleC: rear wheel axle height

D.17

CR 65 2012

A

4

5

6

7

1

2

3



Shock absorber spring preload adjustmentProceed 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.3. Remove the clamp (6) of the tube that connects the filter box to the carburet-

tor.4. Remove the retaining screw (7) that fastens the silencer to the rear chas-

sis.5. Turn the rear chassis upside-down the reach the rear shock absorber adjust-

ing ring nuts.6. Clean lock ring nut (1) and adjuster ring nut (2) of the spring (3).7. Either with a hook wrench or an aluminium punch, loosen the lock ring nut.8. Turn the adjuster ring nut as required.9. Adjust preload to suit your weight or riding style and tighten the lock ring nut

firmly (tightening torque 5 Nm - 0.5 Kgm - 3.69 ft-lb).10. To reassemble the vehicle rear side follow the assembly instructions in the

reverse order.

Be careful not to touch hot exhaust pipe while adjusting the shock ab-sorber.

The standard length of the pre-loaded spring is as

follows:

A= 217 1.5 mm

D.18

CR 65 2012

3

1

2



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. Then turn it back by the mentioned turns. In order to obtain a smooth braking action, turn the adjuster screw counter clockwise. Vice versa to obtain a harder braking action.

It is possible to adjust the compression travel of the shock absorber.

B) COMPRESSION - Standard setting: 1 turn and (from fully closed)

To reset the standard setting, turn upper adjuster screw clockwise (2) until reach-ing fully closed position. Then turn it back by the mentioned turns. In order to obtain a smooth braking action, turn the adjuster screw counter clockwise. Vice versa to obtain a harder braking action.

Shock absorber spring (3)STANDARDK=4.2 daN/mm

Spring preload (shock absorber ring nut)Standard spring length when in its seat 217 mm 1.5Rebound damping (lower screw)Standard 2 turns counterclockwise from end of travelCompression damping (upper screw)Standard 1 turn and counterclockwise from end of trav-

el

D.19

CR 65 2012

1

1

2

2

3



Steering bearing clearance adjustmentFor 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; the handlebar should turn smoothly. Sit on the ground in front of the front wheel and hold the lower ends of the fork legs. Push and pull in a front to rear motion to feel for play.If any play is detected, adjust as follows:

- Loosen the screws (3) with a 6 mm wrench. Loosen and retighten the nut (2) to a torque of 10 Nm - 1.0 Kgm - 7.38 ft/lb.

- Tighten the three screws (3) on the steering head to 25 Nm, 2.5 Kgm, 18.44 ft/Lb.

Handlebar position change

- Remove bumper (1) by cutting the two ties (2) that retain it to the handle-bar.

- It is possible to change the handlebar position to better meet your riding requirements. To do that remove the two upper U-bolts (1) loosening the 4 retaining screws (2).

2

D.20

CR 65 2012

3

4

A A

1

2

3

4



- 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.).

- Tighten the screws (4) to 35 Nm, 3.6 Kgm, 25.81 ft/lb.

- Place the handlebar on the lower clamps paying attention to the correct rout-ing of wires and pipes (they do not have to be twisted).

- Place the upper U-bolts (1) symmetrically and pre-tighten the screws (2) in a crossed pattern in order to have the same front and rear distance (A) between the upper and lower U-bolt.

- Once the handlebar correct inclination has been found, tighten the screws (2) to a torque of 28 Nm (2.85 Kgm - 20.65 ft/lb).

- Keep the same distance (A) during the assembly phase.

- Refit the bumper (3) by fastening it to the handlebar with two plastic ties (4), as shown in the picture.

5

D.21

CR 65 2012

1

2



Tank supply and breather pipe checkMake 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".

Exhaust system checkRemove 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.

Check for any gas leakage between silencer end caps and central pipe (which would indicate a wrongly carried out sealing).

2

1

D.22

CR 65 2012

1

4

5



Sound deadening material replacementRemove 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.

Slide out the external pipe and remove the worn/damaged sound deadening material.

Clean the pipe damaged by any residue of burnt material and oil using first a wire brush and a compressed air jet then.Wrap the damaged pipe up in the new sound deadening material (5), paying utmost attention.

2

3

D.23

CR 65 2012

62



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.

Once the silencer has been reassembled remove any surplus silicone.

Refit the silencer as described under the relevant paragraph; ONLY NOW tighten the rear end cap screws to a torque of 9 Nm.

E.1

CR 65 2012

E

GENERAL PROCEDURES


Section

E.2

CR 65 2012

GENERAL PROCEDURES


Foreword ......................................................................................................E.3Number holder removal ...............................................................................E.4Front mudguard removal .............................................................................E.4Saddle removal.............................................................................................E.5Side panel removal ......................................................................................E.5Rear chassis with rear mudguard and air filter removal .................................E.6Exhaust system removal .............................................................................E.7Fuel tank removal ........................................................................................E.9Carburettor removal from the engine..........................................................E.10Spark plug cap removal .............................................................................E.10Radiator removal ........................................................................................E.10Swinging arm removal ...............................................................................E.12Secondary drive chain removal ..................................................................E.13Clutch actuator removal .............................................................................E.13Generator cable removal ...........................................................................E.14Engine removal from the chassis .............................................................E.14

E.3

CR 65 2012

GENERAL PROCEDURES


ForewordThis 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.

RIGHT-HAND SIDE LEFT-HAND SIDE

E.4

CR 65 2012

1

2

3

4

1

2

GENERAL PROCEDURES


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).

Front mudguard removal- Using an 8 mm wrench, loosen the four screws (1), and remove mudguard

(2).

E.5

CR 65 2012

3

4

3

1

2

12

3

GENERAL PROCEDURES


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).

- Loosen the five retaining screws (3) and remove the left side panel (4).

- Proceed in the same way to remove the right side panel.

E.6

CR 65 2012

1

2

3

4

4

5

GENERAL PROCEDURES


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).

- Use an 8 mm ring wrench (screw) and a 10 mm wrench (nut) to remove the screw and the nut to release the silencer from the rear chassis.

- Use a 12 mm ring wrench to remove the four retaining screws (4) from the rear chassis on both sides.

- Remove the rear chassis with relevant mudguard and air filter (5) from behind releasing the carburettor rubber fitting.

- For reassembly follow the removal procedure in the reverse order having care to correctly fit the rubber fitting (2) on the carburettor so that it does not intake unfiltered air.

- See section "X" for screw tightening torque figures.

E.7

CR 65 2012

9

10

9

GENERAL PROCEDURES


Exhaust system removal

- 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).

- Use an 8 mm ring wrench to release the silencer (9) from the elastic support fastened on the chassis.

Key1 Expansion pipe/silencer2 Gasket3 Springs4 Elastic supports8 Coupling9 Silencer10 Silencer support

E.8

CR 65 2012

9

3

1

7

1

8

GENERAL PROCEDURES


- 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.

- Remove the silencer (1).

E.9

CR 65 2012

2

2

4

5

1

3

GENERAL PROCEDURES


- 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.

Fuel tank removal

- Slide the breather hose (1) out of the steering stem and loosen chassis con-nection screw (2). Pay attention to the bushing under the screw head.

- Turn the ring nut of the fuel cock (3) clockwise to shut off fuel supply and loosen the clamp (4) on the hose running to the carburettor. Detach the hose at carburettor end and let fuel drain into a pan.

- Remove the tank (5) by sliding it from the rear side as shown in the figure.

E.10

CR 65 2012

1

1

1

2

GENERAL PROCEDURES


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.

- Before removing the radiator pipes, empty the cooling system by loosening the screw (2) on the water pump cover.

E.11

CR 65 2012

4

5

6

3

7

1

2

GENERAL PROCEDURES


- 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.

- Open the clamp (5) of the RH radiator connecting lower pipe, and the clamp (6) of engine head connecting pipe (7), using clic clamp pliers (available on the market).

- Remove the two screws (3) that retain the LH radiator to the chassis.

- Remove the LH radiator with head connection pipe (7).

To remove the RH radiator proceed as follows:

- Loosen clamp (1) that fastens the connection pipe (2) to the water pump.

E.12

CR 65 2012

1 2

3

4

5

6

6

GENERAL PROCEDURES


- 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.

Otherwise release the radiator from the two LH radiator connection pipes opening the clamps (6) with the clic clamp pliers, and then disconnect it from the chassis as described above.

Swinging arm removal

- Remove the plug (1) of the shaft nut (2) locking the swinging arm onto the chassis.

E.13

CR 65 2012

3

4B

A

1

2

1

2

3

GENERAL PROCEDURES


- 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.

Secondary drive chain removal

- Remove the case cover (1) to access the drive chain.

- Use needle-nose pliers to remove the master link (2) and open the drive chain.

Clutch actuator removal

- Remove the whole actuator (1) removing the three screws (2) that fasten it to the clutch cover, and release the pipe from the ring (3) that retains it to the engine.

E.14

CR 65 2012

GENERAL PROCEDURES


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.

- Remove the engine from the vehicle left side.

2

1

1

F.1

CR 65 2012

ENGINE DISASSEMBLY


Section F

F.2

CR 65 2012

ENGINE DISASSEMBLY


Preparation ....................................................................................................F.3Gearbox oil drainage procedure ....................................................................F.3Cylinder head, cylinder and piston removal...................................................F.3Water pump disassembly .............................................................................F.4Clutch cover removal .....................................................................................F.5Clutch disassembly........................................................................................F.5Primary drive sprocket removal .....................................................................F.6Kick start pedal shaft removal .......................................................................F.7Gearbox control shaft and selector plate removal .........................................F.7Intake flange and reed valve removal............................................................F.8Starting system disassembly .........................................................................F.8Chain sprocket removal .................................................................................F.9Splitting the crankcase ..................................................................................F.9Gearbox control and shaft removal ...............................................................F.9Process........................................................................................................F.10Crankshaft removal from casing ..................................................................F.10

F.3

CR 65 2012

1

2

6

5

3

4

ENGINE DISASSEMBLY


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.

Gearbox oil drainage procedure Remove the gearbox oil drainage screws (1) with relevant sealing ring and

drain the gearbox oil.

Cylinder head, cylinder and piston removal Loosen the spark plug. Remove all cylinder head screws (2) and the head itself.

Remove the two O-rings (3) from the cylinder grooves. Remove both centring bushings (4). Loosen the two clamps (5) and remove the water pipe. Remove the exhaust pipe fitting (6) and its gasket by loosening the two

screws. Remove the four flanged nuts from the cylinder base. Carefully lift the cylinder up.

F.4

CR 65 2012

BA

1

1

ENGINE DISASSEMBLY


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. Remove the cylinder base gaskets.

Water pump disassembly

WARNING: It is not necessary to disassemble the water pump to remove the clutch cover.

The water pump remains inside the clutch cover. The water pump features a hole A where spring B is located.

Loosen the three screws and remove the water pump with its O-rings. Remove the circlip (1) and slide the water pump impeller out of the shaft.

WARNING: If the water pump impeller is fastened inside the crankshaft it is pos-sible to slide it out along with the clutch cover by loosening the cover screws.

F.5

CR 65 2012

2

3

4

5

1

ENGINE DISASSEMBLY


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)).

Remove both centring bushings. Remove the spring (2) of the starting coupling, the thrust washer (3) and the

thrust bearing (4).

Slightly turn the starting coupling (5) counterclockwise and slide it out of the kick start pedal shaft.

Clutch disassembly Place the retainer (1) on the hub and loosen the hexagonal-head screw. Remove the hexagonal-head screw.

F.6

CR 65 2012

2

45

3

6

ENGINE DISASSEMBLY


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.

Slide out the thrust washer from the input shaft, the clutch housing, the sup-porting bushing (3) and the thrust washer (4) placed behind.

Remove the starting idle gear (5).

Primary drive sprocket removal

Place the retaining tool (6) for the primary drive sprocket and loosen the hexagon nut.

TO LOOSEN THE HEXAGON NUT OF THE PRIMARY DRIVE SPROCK-ET, THE PRIMARY DRIVE MUST NOT BE BLOCKED WITH A SECTOR GEAR OR ALIKE. THAT WOULD DAMAGE THE CRANKSHAFT.

Remove the retaining tool, the hexagon nut, the lock washer and the primary drive sprocket from the crankshaft.

Use the puller to remove the gear from the crankshaft.

F.7

CR 65 2012

1

3

2

4

5

ENGINE DISASSEMBLY


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.

Remove the screw (4) and slide the selector plate out of the selector drum.

Remove the circlip (5), the selector lever and spring.

F.8

CR 65 2012

1

43

1

2

ENGINE DISASSEMBLY


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).

Hold the rotor and using the suitable wrench remove the flanged nut with its elastic washer.

Screw the special puller (2) onto the rotor, keep the puller and by holding the extraction screw slide the rotor out of the crankshaft.

Loosen the three screws (3) of the stator and remove the latter (4). Remove the engine wiring ring from the crankcase. Have care not to loose the key.

F.9

CR 65 2012

1

2

3

44

6

5

5

5

ENGINE DISASSEMBLY


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. Remove the engine retainers on the installation stand. Detach the right crankcase half using suitable tools correctly positioned in

the relevant places, or gently tapping on the output shaft and crankshaft with a plastic hammer.

AVOID SEPARATING THE CRANKCASE HALVES WITH A SCREW-DRIVER OR SIMILAR TOOLS THAT CAN EASILY DAMAGE THE SEALING SURFACES.

Gearbox control and shaft removal Remove the left crankcase half and the relevant gasket.

WARNING: While removing the left crankcase half be careful not to damage the washers on the input shaft and the selector drum. They can be fastened inside the crankcase half.

Remove the thrust washer (3) and the shim (2). Slide the 2 centring bushings out of the casing. Remove the O-ring from the output shaft. Fasten the right crankcase half onto the installation stand. Pull up the fork guiding rods (4) by nearly 1.5 cm and move them aside to-

gether with the gearbox forks (5). Remove the selector drum (6) with the relevant shim (if any) from the cas-

ing.

WARNING: The shims on the selector drum compensate the axial clearance. Upon reassembly they must be refitted in the original position.

Remove the fork guiding rods and the gearbox forks from the casing.

WARNING: The gearbox forks of the output shaft are the same, but despite that, they

should be refitted in the original position.For this reason mark them upon disassembly.

The fork guiding rods are loaded by means of a spring, so it is recommendable to slide them upwards from the gearbox forks. In this way the upper spring remains in the rod and the lower one must be removed from the casing. Then the gearbox forks can be moved aside.

MAKE SURE THE BUSHINGS DO NOT FALL FROM THE GEARBOX FORKS.

F.10

CR 65 2012

1

ENGINE DISASSEMBLY


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.

Crankshaft removal from casing Use the two threaded rods to fasten the special tool (1) to the crankcase half

and pull the crankshaft out of the crankcase half.

WARNING: If the procedure described above is not possible, heat the crankcase half up to nearly 100C.

Clean all parts, check them for wear and replace if necessary.

WARNING: In case of engine overhaul we recommend to replace all gaskets, oil seals, O-rings and bearings.

UPON REMOVAL OF CRANKSHAFT HAVE IT KEPT BY ANOTHER PERSON TO PREVENT IF FROM FALLING DOWN AND GETTING DAMAGED.

G.1

CR 65 2012

ENGINE OVERHAUL


Section G

G.2

CR 65 2012

ENGINE OVERHAUL


Engine crankcase (crankcase half) ..............................................................G.3Actions on left crankcase half .......................................................................G.4Actions on right crankcase half.....................................................................G.5Crankshaft measurement .............................................................................G.6Actions on clutch cover.................................................................................G.6Water pump disassembly and inspection .....................................................G.7Piston check .................................................................................................G.8Piston ring gap measurement.......................................................................G.8Piston and cylinder measurement, piston assembly clearance determination..........................................................................G.8Reed valve, intake flange .............................................................................G.9Gearbox control shaft disassembly ............................................................G.10Gearbox control check for component wear ............................................G.10Gearbox control shaft pre-assembly...........................................................G.10Clutch check for component wear ...........................................................G.11Plate pack pre-assembly ............................................................................G.11Kick start pedal shaft pre-assembly............................................................G.12Gearbox shafts check for component wear .............................................G.12Input shaft assembly...................................................................................G.13Output shaft assembly ................................................................................G.13

G.3

CR 65 2012

ENGINE OVERHAUL


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. To this end we recommend using a wood plane.

Bearings and sealing rings should never be fitted without a suitable press, otherwise pay utmost attention and use other suitable tools. When the casings reach 150 C cold bearings fall in the relevant seats without any effort.

If the bearings are not well seated after cooling down, it is probable that they will turn in their seats upon following operation: it is thus necessary to replace the crankcase.

G.4

CR 65 2012

3

4

2

1

3

5

6

7

S

ENGINE OVERHAUL


Actions on left crankcase halfRemove 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. If necessary, press the bearing out.The tools (punches) to insert the new bearings shall be so designed to lay on the external ring of the bearings. Otherwise the bearings will be already dam-aged upon assembly.

Crankshaft ball bearing (1)Use a suitable punch to push the ball bearing from the outside. Push the new ball bearing from the inside fully home.

Output shaft ball bearing (2)Use a suitable punch to push the ball bearing from the outside. Push the new ball bearing from the inside fully home.

Input shaft needle roller bearing (3)Use a suitable 12-16 mm puller to remove the needle roller bearing from the casing. Push the new needle roller bearing fully home.

Selector drum ball bearing (4)Use a suitable puller to remove the roller bearing from the casing. Push the new ball bearing fully home.

Engine oil seal (5)From the outer side, force the new oil seal in with the sealing lip inwards.

Output shaft oil seal (6)From the outer side, force the new oil seal in with the sealing lip inwards.

Gearbox control shaft oil seal (7).From the outer side, force the new oil seal in with the sealing lip inwards.

After crankcase half has cooled down check that all bearings are properly po-sitioned in their seats.Then make sure the lubrication hole (S) for the crankshaft ball bearing is free.

G.5

CR 65 2012

6

1

2

5

2

3

78

9

ENGINE OVERHAUL


Actions on right crankcase halfRemove 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. If necessary, press the bearing out.The tools (punches) to insert the new bearings shall be so designed to lay on the external ring of the bearings. Otherwise the bearings will be already dam-aged upon assembly.

Crankshaft ball bearing (1)Use a suitable punch to push the ball bearing from the outside. Push the new ball bearing from the inside fully home.

Input shaft ball bearing (2)Remove screw (3).

WARNING: To improve the seat, the crankshaft ball bearing is fastened with a screw to the casing on engines from model '99. Remove such screw before extracting the bearing.Use a suitable punch to push the ball bearing from the outside.Push the new ball bearing from the inside fully home.Smear Loctite 243 on the screw (3) thread and fit it.

LIGHTLY PUSH THE NEW NEEDLE ROLLER BEARING AGAINST THE CASING TO AVOID DAMAGING THE LATTER.

Selector drum ball bearing (5)Use a suitable punch to push the ball bearing from the outside.Push the new ball bearing from the inside fully home.

Output shaft needle roller bearing (6)Use a suitable punch to push the needle roller bearing from the outside.Push the new needle roller bearing from the inside.

Engine oil seal (7)From the outer side, force the new oil seal in with the sealing lip inwards.

Idle gear supporting pin (8)According to our experience it is not necessary to replace the supporting pin. Nevertheless, to replace it remove the socket head screw from the supporting pin and remove it. Upon assembly smear some Loctite 243 on the socket head screw.

Selector lever supporting pin (9)Use a socket wrench to remove the supporting pin from the selector lever. Upon assembly smear some Loctite 243 on the supporting pin.

When the crankcase half has cooled down check the bearings are properly seated.

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Then make sure the lubrication hole (S) for the crankshaft ball bearing is free.

Crankshaft measurementAlways 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.

Max. radial clearance 0.03 mm

Actions on clutch coverKick start pedal shaft oil seal (1)Push the old oil seal from inside out. Force the new oil seal in from outside (with open side inwards).

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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.

WARNING: If the ball bearings remain in the casing they can be extracted from the clutch cover using a suitable puller.

Water pump oil seal Push the old oil seal from inside out.

From the outer side, force the new oil seal in with the open side outwards.

Water pump ball bearings Slide both bearings out of the water pump shaft. First key the ball bearing fully against the shaft. Then key the ball bearing

sealed on both sides.

Grease the water pump oil seal. Force the water pump shaft completely inside the clutch cover. Then make

sure the water pump shaft moves freely. Insert the water pump impeller on the shaft and fit the circlip (3).

CHECK THE CIRCLIP SEAT. OTHERWISE THE WATER PUMP IMPEL-LER COULD LOOSEN.

Screw the water pump cover with its seal on the clutch cover and tighten the screws to 10 Nm.

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Piston checkCheck 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).

3. The piston ring retainer must be firmly placed in the piston and must not be worn out.

4. Check piston ring wear and gap.

Piston ring gap measurement Insert the piston ring in the cylinder and align it with the piston (ca. 10 mm

under the cylinder upper edge). Use a feeler gauge to measure the piston ring gap (B).

Piston ring gap: max. 0.35 mm

WARNING: If the value exceeds the indicated one check the piston ring and cylinder wear. If the piston and cylinder wear respect the tolerances, replace the piston ring.

Piston and cylinder measurement, and piston assembly clearance deter-mination. To determine the cylinder wear, the cylinder is measured by means of a feeler

gauge placed 10 mm and 50 mm under the sliding surface upper edge. Measure the cylinder diameter on X and Y axes to detect any ovalization.

The piston shall be measured on its skirt transversal to the piston pin, nearly 50 mm under the piston upper edge and nearly above the slot.

The piston assembly clearance is obtained by subtracting the piston maximum diameter from the cylinder minimum diameter.

Piston installation clearance: 0.065 - 0.075 mm

WARNING: If the piston installation clearance exceeds 0.09 mm, it is necessary to fit a bigger piston. If this happens with a piston marked with "E/F", it is neces-sary to replace both cylinder and piston.

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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.

Always consider there must be an installation clearance of 0.065 mm!

MARKING PISTON MEAS. CYLINDER MEAS. A 44.955 44.960 mm 45.025 45.030 mm B 44.961 44.965 mm 45.031 45.035 mm C 44.966 44.970 mm 45.036 45.040 mm D 44.971 44.975 mm 45.041 45.045 mm E 44.976 44.980 mm 45.046 45.050 mm

Reed valve, intake flange

WARNING: Over time the reeds loose tension with a consequent power loss. Damaged or worn out reeds shall be replaced.If the reed valve surfaces are damaged, replace the whole reed valve.

Intake flange

Make sure there are no cracks or other damages.

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3

4

5

6

7

7

8

711

119

12

12

12

12

10

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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). Remove the compression spring (5) by moving the sliding plate (3) and remov-

ing it from the selector (4).

Gearbox control component wear checkSliding plate (3)Check wear on engagement points on the shaped selector plate.Check the sliding plate return surface wear (replace if too much notched).

Selector (4)Check wear on engagement points on the shaped selector plate.Check the guiding pin fixed seat and wear.

Compression spring (5)Check the compression spring pre-load for the sliding plate.

Gearbox forks (7)Check for wear of gearbox fork end parts and of the selector drum driving dowels.

Selector drum (8)Check for wear of the shaped grooves.Check for wear of selector drum supporting points.

WARNING: The selector drum (8) is on ball bearings (10) and the fork guiding rods (11)

are loaded by means of a spring (12).

Gearbox control shaft pre-assembly Insert the sliding plate in the selector and move it. Now it is possible to insert the compression spring. Remove the grease from the spring holder thread and lightly smear Loctite

243. Fit the sliding plate together with the selector on the gearbox control shaft and fasten with the spring holder.

Fit the return spring.

WARNING: The return spring shall be fitted with curved part faced up.

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LOCTITE 243

1

27

5

6

A 34

B

LOXEAL 86-54

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Clutch check for component wearCheck 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.

5 steel plates (4)The steel plates must be flat and feature a minimum thickness of 0.95 mm.

Clutch hub (5)Check that the steel plate thrust surfaces are not damaged.Check the bearing surface A of the lined plate. If the pitting exceeds 0.50 mm, replace the hub.

Clutch housing (6)Check the thrust surfaces B wear of the lined plates. If the pitting exceeds 0.50 mm, replace the clutch housing.

Supporting bushing (7) Insert the supporting bushing in the clutch housing and check the clearance.

Plate pack pre-assembly Fasten the input shaft in the vice (use protection jaws). Insert the thrust washer (1.50 mm), the supporting bushing and the clutch

housing. Insert the pressure plate. Alternatively insert 6 lined plates and 5 steel plates starting with a lined plate.

Finish with a lined plate. Insert the spring retaining plate, start, pre-tighten and then tighten the socket

screws to 12 Nm. Remove the plate pack from the clutch housing.

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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. Engage the kick start pedal spring (6) in the suitable hole of the kick start pedal

shaft and fit the driving hub (7) with opening A above the spring end part. Remove the kick start pedal shaft from the vice.

Gearbox shafts component wear check Fasten the input and output shafts in the vice (useprotection jaws). Remove the gears and check for wear and seizure signs in the following points: the supporting points of the input and output shafts, and of the neutral

gears; the gear front couplings; the teeth sides of all gears; the toothing profiles of the input and output shafts and of the relevant

gears; check the smoothness of the gearbox gear contours.

Thoroughly clean all parts and replace the faulty ones.Upon each repairing of the gearbox first mount the new circlips.

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7 21

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Input s

Documents

Repair Manual Husqvarna CR 65 2012