Husqvarna WRE 125 (2011), SMS 125 (2011) Workshop Manual

Workshop Manual

WRE 125 2011

SMS 125 2011

Ed. 05-2011

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 reect on-going product development. Illustrations in the

manual may differ from actual components. No reproduction in full or in
part without written authorisation.
1st edition (05-2011)

a.1

H02627

1

FOREWORD, TABLE OF CONTENTS

Ed. 05-2011

1st edition (05-2011)
Printed in Italy

MODELS COVERED (from serial number onwards)

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

Workshop Manual

1. Chassis serial number

TE 250 - 310 2011 I.E.

WRE 125 2011

SMS 125 2011

WRE 125: ZKHH200AABV000000

SMS 125: ZKHH200ABBV000000

a.2

FOREWORD, TABLE OF CONTENTS

Ed. 05-2011

Foreword

This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance
and repair of the models covered in this manual. The technical information provided in this manual is a critical comple­ment 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 signicance are identied as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from incompliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tips

To 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 specic 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 practices

1 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-

ed 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 specied.

6 Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read

them.

a.3

FOREWORD, TABLE OF CONTENTS

Ed. 05-2011

Table of Contents

Title Section

Foreword, Table of Contents ...............................................................................a

Important Notices ................................................................................................b

General Information .............................................................................................A

Maintenance ........................................................................................................B

Troubleshooting .................................................................................................. C

Settings and Adjustments ................................................................................... D

General Procedures ............................................................................................E

Engine Disassembly ............................................................................................F

Engine Overhaul .................................................................................................G

Engine Assembly ................................................................................................ H

Front Suspension .................................................................................................I

Rear Suspension ................................................................................................. J

Brakes .................................................................................................................L

Electrical System ................................................................................................M

Engine Cooling ................................................................................................... N

Special Tools ......................................................................................................W

Tightening Torque Figures ...................................................................................X

Chassis and Wheels ............................................................................................Y

NOTES

Unless otherwise specied, data and specications apply to all models.

b.1

b

IMPORTANT NOTICES

Ed. 05-2011

Section

b.2

H02628

WRE 125

H02629

SMS 125

SMS 125

H02630

H02631

SMS 125

IMPORTANT NOTICES

Ed. 05-2011

WRE and SMS models are STREET LEGAL motorcycles; they are guaranteed
exempt from functional defects and covered with legal guarantee, as far as the
STANDARD CONFIGURATION IS MAINTAINED and the suggested mainte­nance table, shown in Section B, is observed.

* This motorcycle has not been designed to travel over long distances with the

engine at top rpm, as in long-distance road or highway travel. Riding over
long distances at full throttle may result in severe engine damage.

IMPORTANT

VEHICLE CONFIGURATION as outlined below is a prerequisite for the war­ranty to remain valid:
A) STANDARD MOTORCYCLE, FOR ROAD USE: DERATED;

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must
follow the maintenance programme indicated in Section B by having the required
maintenance inspections carried out at authorised HUSQVARNA dealers. The
cost for changing parts and for the labour necessary in order to comply with
the maintenance plan is charged to the Client. The warranty becomes NULL
AND VOID if the motorcycle is rented.

Notes
Left and right side is determined when seated on motorcycle.

Unless otherwise specied, data and instructions apply to all market variants.

A.1

A

GENERAL INFORMATION

Ed. 05-2011

Section

A.2

GENERAL INFORMATION

Ed. 05-2011

ENGINE ........................................................................................................A.3

Starting .........................................................................................................A.3

TIMING SYSTEM .........................................................................................A.3

LUBRICATION ..............................................................................................A.3

IGNITION ......................................................................................................A.3

FUEL SYSTEM .............................................................................................A.3

PRIMARY DRIVE .........................................................................................A.3

CLUTCH .......................................................................................................A.3

TRANSMISSION ..........................................................................................A.3

Transmission ratio ........................................................................................A.3

SECONDARY DRIVE (WRE) .......................................................................A.4

SECONDARY DRIVE (SMS) ........................................................................A.4

FINAL RATIOS (WRE) ..................................................................................A.4

FINAL RATIOS (SMS) ..................................................................................A.4

FRAME .........................................................................................................A.4

FRONT SUSPENSION .................................................................................A.4

REAR SUSPENSION ...................................................................................A.4

FRONT BRAKE ............................................................................................A.4

REAR BRAKE ..............................................................................................A.4

RIMS .............................................................................................................A.4

TIRES ...........................................................................................................A.4

Cold tire pressure ........................................................................................A.5

Electrical components location .....................................................................A.5

Overall dimensions .......................................................................................A.6

Weight ..........................................................................................................A.6

Capacities .....................................................................................................A.7

A.3

GENERAL INFORMATION

Ed. 05-2011

ENGINE

Type .............................................................................. single cylinder, 2 stroke

Cooling ......................................................................................................liquid

Bore ......................................................................................... mm 54 (2.12 in.)

Stroke ................................................................................... mm 54,5 (2.14 in.)

Displacement .............................................................. cm3 124,82 (7.61 cu. in.)

Compression ratio (with closed ports) ........................................................8,8:1

STARTING

Type..................................................................................................... kick start

TIMING SYSTEM

Type ................................................. reed valve at intake in the crankcase and

H.T.S. valve with mechanical control at the exhaust

LUBRICATION

Motore .....................................................................................by electric pump

Primary drive transmission/Gearbox ...... by the oil contained in the crankcase

IGNITION

Type .......... ...............................................................................electronic C.D.I.

Spark plug type..............................................CHAMPION QN 84/NGK BR9EG

Spark plug gap ...................................................................0,6 mm (0.0236 in.)

FUEL SYSTEM

Type ............................................................Carburettor DELL’ORTO VHST 28

Venturi diameter ...................................................................... mm 28 (1.10 in.)

High speed jet...............................................................................................142

Low speed jet ................................................................................................38

Starting jet .....................................................................................................60

Main nozzle ...........................................................................................HN 268

Floater ........................................................................................................g 6,5

Throttle valve ..................................................................................................55

Metering pin ................................................................................................D 48

Metering pin slot ......................................................................................2nd (*)

Idle mixture adjusting screw .............................................................1+1/2 turns

PRIMARY DRIVE

Drive pinion gear ....................................................................................... Z 22

Clutch ring gear .......................................................................................... Z 72

Transmission ratio .....................................................................................3,272

CLUTCH

Type .........................................oil bath multiple disc clutch, mechanical control

TRANSMISSION

Type ............................................................................ constant mesh gear type

Transmission ratio

1st gear. .....................................................................................2,692 (Z 35/13)

2nd gear ....................................................................................1,800 (Z 27/15)

3rd gear ....................................................................................1,333 (Z 24/18)

4th gear......................................................................................1,100 (Z 22/20)

5 th gear.....................................................................................0,954 (Z 21/22)

6 th gear ....................................................................................0,869 (Z 20/23)

(*): with washer between retainer and throttle valve

A.4

GENERAL INFORMATION

Ed. 05-2011

SECONDARY DRIVE (WRE)

Transmission sprocket ............................................................................... Z 13

Rear wheel sprocket ................................................................................... Z 49

Transmission ratio .....................................................................................3,769

SECONDARY DRIVE (SMS)

Transmission sprocket................................................................................ Z 14

Rear wheel sprocket ................................................................................... Z 49

Transmission ratio .....................................................................................3,500

Transmission chain dimensions ..........................................................5/8”x1/4”

FINAL RATIOS (WRE)

1st gear....................................................................................................33,211

2nd gear ..................................................................................................22,204

3rd gear ...................................................................................................16,447

4th gear ...................................................................................................13,569

5th gear ...................................................................................................11,775

6th gear ...................................................................................................10,727

FINAL RATIOS (SMS)

1st gear....................................................................................................30,839

2nd gear ..................................................................................................20,618

3rd gear ...................................................................................................15,273

4th gear ...................................................................................................12,600

5th gear ...................................................................................................10,934

6th gear .....................................................................................................9,960

FRAME

Type ................................. single frame, in circular sectioned tubes, in steel; rear steel chassis.

FRONT SUSPENSION

Type ................................................ ”Upside-down” telescopic hydraulic front fork with advanced

axle; ...............................................stanchions tubes Ø 1.57 in. / ø 40 mm

Legs axis stroke................................................................... 260 mm (10.24 in.)

REAR SUSPENSION

Type ...................................... progressive with hydraulic single shock absorber

(spring preload adjustment)

Wheel stroke ...................................................................... 272 mm (10.71 in.)

FRONT BRAKE

Type................................. fixed disc Ø 260 mm (10.24 in.) with hydraulic control and floating calliper

REAR BRAKE

Type................................. fixed disc Ø 220 mm (8.66 in.) with hydraulic control and floating calliper

RIMS

Front (WRE) ......................................................................in light alloy: 1,6x21”

Front (SMS) .................................................................... in light alloy: 2,50X17”

Rear (WRE) .....................................................................in light alloy: 2,15x18”

Rear (SMS) ......................................................................in light alloy: 1,85x19”

TIRES

Front

(WRE) .................................................................................................90/90-21”

(SMS) ................................................................................................110/70-17”

Rear

(WRE) ...............................................................................................120/90-18”

(SMS) ...............................................................................................140/60-17”

A.5

GENERAL INFORMATION

Ed. 05-2011

Cold tire pressure

Front

Rider only .......................................................................1,2 Kg/cm

2

(17.07 Psi)

Rider and passenger ......................................................1,5 Kg/cm

2

(21.33 Psi)
Rear

Rider only .......................................................................1,5 Kg/cm2 (21.33 Psi)

Rider and passenger ......................................................1,8 Kg/cm2 (25.60 Psi)

Electrical components location

The ignition system includes the following elements:

- Generator, on the inner side of L.H. crankcase cover;

- Electronic ignition coil under the fuel tank;

- Electronic control unit under the saddle;

- Voltage regulator on the left side of the chassis, near the steering tube.

- Spark plug on cylinder head;
The electrical system includes the following elements:

- 12V-4Ah Battery under the saddle;

- Turning indicator asher on left side of rear chassis;

- Fuses located on services bracket on left hand side of subframe;

- Oil pump located on right hand side of rear subframe;

- Air temperature sensor located inside lter box, near oil pump.

- Engine temperature sensor;

- Headlamp with twin halogen bulb of 12V-35/35W and parking light bulb of 12V-3W;

- LED taillight;

- Turning indicators 12V-10W bulb;

- Horn up front on right side, near the radiator.

A.6

H02633

WRE 125

GENERAL INFORMATION

Ed. 05-2011

Overall dimensions

Wheelbase A

(WRE) ................................................................................ mm 1462 (57.56 in.)

(SMS) ................................................................................mm 1462 (57.56 in.)

Overall length B

(WRE) ................................................................................ mm 2208 (86.93 in.)

(SMS) ................................................................................mm 2145 (84.49 in.)

Overall width C .................................................................... mm 825 (32.48 in.)

Overall height D

(WRE) ................................................................................ mm 1245 (49.01 in.)

(SMS) .................................................................................mm 1175 (46.26 in.)

Saddle height E

(WRE) .................................................................................. mm 944 (37.16 in.)

(SMS) ..................................................................................mm 929 (36.57 in.)

Minimum ground clearance F

(WRE) .................................................................................. mm 330 (13.00 in.)

(SMS) ..................................................................................mm 265 (10.43 in.)

Weight

Kerb weight, without fuel (WRE):........................................ 108 Kg (238,01ß lb)

Kerb weight, without fuel (SMS): ...........................................111 Kg (244,71 lb)

A.7

H02634

SMS 125

GENERAL INFORMATION

Ed. 05-2011

Capacities Type Quantity

Fuel tank capacity (reserve included) 98 octane unleaded fuel 9,5 l - 2.09 Imp. Gall

2.51 U.S. Gall
Fuel reserve 2 l - 0.44 Imp. Gall

0.53 U.S. Gall
Oil tank capacity 0.176 Imp. Gall

0.211 U.S. Gall
Coolant capacity 0.22 Imp. Gall

0.26 U.S. Gal
Transmission oil 0.143 Imp. Gall

0.172 U.S. Gall
Engine lubricating oil CASTROL POWER 1 RACING 2T

Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 5W-40
Engine coolant CASTROL MOTORCYCLE COOLANT

Brake system uid CASTROL RESPONSE SUPER DOT 4

Grease lubrication CASTROL LM GREASE 2
Final drive chain lubrication CASTROL CHAIN LUBE RACING
Front fork oil CASTROL SYNTHETIC FORK OIL 5W 520 cm

3

Electric contact protection CASTROL METAL PARTS CLEANER
Fillers for radiator AREXONS TURAFALLE LIQUIDO

IMPORTANT - Do not add any additives to fuel or lubricants.

B.1

B

MAINTENANCE

Ed. 05-2011

Section

B.2

MAINTENANCE

Ed. 05-2011

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

ENGINE

PART

EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE

500 km (310 mi) 1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi)

20000 Km (12427 mi)

AS REQUIRED

TRANSMISSION OIL

C S S S S

ENGINE OIL

C

COOLANT

C C S C S X

SPARK PLUG

C S S S S

PISTON/CYLINDER

C C C C X

EXHAUST VALVE DECARBONIZING

P P P P X

CLUTCH DISC

C C C C X

AIR FILTER

P P S P S

CARBURETOR:IDLE/CO

C C

CARBURETOR

C/P C/P C/P C/P C/P

EXHAUST VALVE CLEANING / OIL DRAINAGE

P

WRE - SMS 125

LEGENDA
C: CHECK
P: CLEAN
C/P: CHECK / CLEAN
S: CHANGE

B.3

MAINTENANCE

Ed. 05-2011

SCHEDULED MAINTENANCE CHART

(TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

CHASSIS

PART

EVERY AFTER THE FIRST EVERY EVERY EVERY EVERY REPLACE

3 HOURS

1000 Km (621 mi) 5000 Km (3106 mi) 10000 Km (6213 mi) 15000 Km (9320 mi)

20000 Km (12427 mi)

AS REQUIRED

BRAKE FLUID

C C S C S

BRAKE HYDRAULIC CONTROLS

C C C C C X

BRAKE PADS WEAR

C C C X

BOWDEN CABLES

C L L L L X

THROTTLE

C C C C C X

TYRE PRESSURE AND WEAR

C C C C C

OIL AND FUEL TANKS

P P

FUEL HOSES AND FILTERS

P P S P S

HEADLAMP BEAM HEIGHT

C C C C C

LIGHTS/INDICATIONS/HORN

C C C C C

BATTERY

C C C C C

WHEEL SPOKES TENSION

C C C C C

STEERING BEARINGS PLAY

C C C

SECOND.DRIVE CHAIN/CHAIN TENS.ROLLERS

C C C C C C

GEARB.OUTPUT SPROCKET/REAR SPROCKET

C S C S

SIDE STAND SCREWS

C C C C C

WHEEL HUB BEARINGS

C C X

FRONT FORK FLUID

S S

OVERALL TIGHTENING OF NUTS AND BOLTS

C C C C C

LUBRICATION/GREASING

L L L L L

LEGEND
C: CHECK
L: LUBRICATE
P: CLEAN
S: CHANGE

NOTES:

- REPLACE GASKETS AND SEALS AFTER EACH REMOVAL;

- REPLACE SCREWS AND BOLTS IF DAMAGED;

- PERFORM A GENERAL INSPECTION AFTER RIDING ON MUDDY OR SANDY TERRAIN.

WRE - SMS 125

C.1

C

TROUBLESHOOTING

Ed. 05-2011

Section

C.2

TROUBLESHOOTING

Ed. 05-2011

ENGINE

Trouble Cause Remedy

Engine does not start or has starting trou­bles

Insufcient compression

1. Piston seized Replace

2. Connecting rod small or big end seized Replace

3. Worn piston ring Replace

4. Worn cylinder Replace

5. Cylinder head loosely tightened Tighten

6. 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

6. Key-operated switch faulty Replace

The carburettor is not receiving fuel

1. Tank cap breather clogged Clean

2. Fuel cock clogged Clean

3. Clogged fuel inlet hose Clean

4. Floater valve faulty Replace

5. Linkage is blocking oater valve Release

Carburettor oods

1. High fuel level in bowl Adjust

2. Floater valve worn or stuck open Replace or release

Engine lubrication

1. Electric oil pump faulty or dirty Check

Engine stalls easily 1. Fouled spark plug Clean

2. Electronic control unit faulty Replace

3. Carburettor jets clogged Clean

4. Low idle Adjust

C.3

TROUBLESHOOTING

Ed. 05-2011

Trouble Cause Remedy

Engine is noisy Noise seems to come from piston

1. Too much piston-to-cylinder clearance Replace

2. Worn piston rings or piston grooves Replace

3. Too much carbon build-up in combustion chamber
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 clear­ance or end oat

Replace

3. Crankshaft gear damaged Replace

4. Countershaft not correctly installed Install correctly

5. Crankshaft and countershaft gears damaged Replace

Noise seems to come from the clutch

1. Worn plates Replace

2. Too much clearance between clutch housing and
friction plates

Replace

Noise seems to come from gearbox

1. Worn gears Replace

2. Worn gear grooves Replace

Noise seems to come from the secondary
drive chain

1. Chain stretched (worn) or improperly adjusted Replace or adjust

2. Worn transmission sprockets Replace

The clutch slips 1. Clutch adjuster screw with insufcient clearance Adjust

2. Weak clutch springs Replace

3. Worn clutch plates Replace

The clutch is tight 1. Clutch adjuster screw with exceeding clearance Adjust

2. Non uniform spring load Replace

3. Bent clutch plates Replace

The gears cannot be inserted. 1. Clutch does not disengage Adjust

2. Bent or seized shifter forks Replace

3. Worn gear ratchets Replace

4. Damaged shifter fork shafts Replace

C.4

TROUBLESHOOTING

Ed. 05-2011

Trouble Cause Remedy

Gear shift pedal does not return to original
position

1. Weak or broken selector return spring Replace

2. Worn shifter forks Replace

Transmission jumps out of gear 1. Worn sliding gear dogs Replace

2. Worn gear grooves Replace

3. Worn dog slots in gears Replace

4. Worn selector shaft splines Replace

5. Worn shifter fork shafts Replace

6. Worn shifter forks Replace

Engine has low power 1. Dirty air lter Clean

2. Poor fuel quality Replace

3. Intake coupling loose Tighten

4. Spark plug electrode gap too wide Adjust

5. Insufcient compression Check for the cause

6. Carburettor main jet clogged or of the wrong size Clean or replace

7. Too much ignition advance Adjust

8. Deposits on the exhaust valve Clean

9. Exhaust valve wrongly installed Adjust

The engine overheats 1. Dirty combustion chamber and/or piston crown

with carbon deposits

Clean

2. Insufcient oil in engine or wrong oil Top up or change

3. Obstructions blocking air ow on radiator Clean

4. Cylinder head gasket leaking Replace

5. The clutch slides Adjust

6. Too much ignition delay Adjust

Coolant drops around spark plug elec­trodes

1. Cylinder head gasket leaking Replace

2. Porosities inside head dome Replace

Oil level increase inside crankcase due to the
presence of coolant

1. Water pump impeller shaft leaking Check

C.5

TROUBLESHOOTING

Ed. 05-2011

CHASSIS

Trouble Cause Remedy

The handlebar is hard to turn 1. Insufcient tyre pressure Inate

2. Bearing adjuster ring nut or steering stem nut

overtightened

Adjust

3. Bent steering stem Replace bottom yoke

4. Worn or seized steering bearings Replace

Handlebar vibration 1. Bent fork legs Replace

2. Bent front wheel axle Replace

3. Warped chassis Replace

4. Bent front wheel rim Replace

5. Worn front wheel bearings Replace

Damping is too hard 1. Too much oil in fork legs Remove excess oil

2. Fork oil viscosity too high Replace

3. Overinated tyres Deate

4. Improperly set rear shock absorber Adjust

Damping is too soft 1. Insufcient oil in fork legs Top up

2. Fork oil viscosity too low Replace

3. Damping cartridge inside fork legs is not working

properly

Replace

4. Weak rear shock absorber spring Replace

5. Improperly set rear shock absorber Adjust

(Front and rear ) wheel vibrates 1. Bent wheel rim Replace

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 noisy 1. Worn link rod spacers or bearings Replace

2. Worn shock absorber ball joints Replace

3. Shock absorber faulty Replace

Poor braking
(front and rear)

1. Air in brake system Bleed

2. Insufcient uid in tank Top up

3. Worn brake pad and/or disc Replace

4. Damaged disc Replace

5. Improperly adjusted brake pedal Adjust

6. Water in brake system Change uid

C.6

TROUBLESHOOTING

Ed. 05-2011

ELECTRICAL SYSTEM (see also Section M)

Trouble Cause Remedy

The spark plug gets dirty easily 1. Dirty air lter Clean

2. Worn piston rings Replace

3. Worn piston or cylinder liner Replace

4. Mixture too rich Adjust carburettor

Spark plug electrodes overheat 1. Spark plug electrode gap too close Adjust

2. Heat rating too high Replace with recommend­ed spark plug

3. Mixture too lean Adjust carburettor

Generator does not charge or is not provid­ing enough charge

1. Cables running to voltage regulator

improperly connected or shorted

Connect correctly or
replace

2. Voltage regulator faulty Replace

3. Generator coil faulty Replace

Generator overcharges battery 1. Voltage regulator faulty Replace

Battery does not hold charge 1. Battery terminals dirty Clean

Battery sulphation 1. Charge voltage too high or too low (when they

are not used, batteries should be recharged at
least once a month)

Replace battery

D.1

D

SETTINGS AND ADJUSTMENTS

Ed. 05-2011

Section

D.2

SETTINGS AND ADJUSTMENTS

Ed. 05-2011

Saddle removal.............................................................................................D.4

Tank removal ................................................................................................D.4

Throttle cable adjustment .............................................................................D.6

Adjustment of the starter lever......................................................................D.6

Idle adjustment .............................................................................................D.7

Clutch plate replacement ..............................................................................D.8

Adjustment of the clutch control lever ..........................................................D.9

Front brake uid level check ......................................................................D.10

Rear brake pedal position adjustment ........................................................D.11

Rear brake pedal free play adjustment.......................................................D.11

Rear brake uid level check .......................................................................D.12

Checking the oil level..................................................................................D.12

Changing transmission/gearbox oil ............................................................D.13

Engine lubrication oil level ..........................................................................D.14

Exhaust valve cleaning / oil drainage .........................................................D.14

Lubricating oil pump drainage ....................................................................D.15

Coolant level check ....................................................................................D.16

Coolant replacement ..................................................................................D.17

Air lter check .............................................................................................D.18

Air lter cleaning .........................................................................................D.18

Assembly ....................................................................................................D.19

Chain adjustment .......................................................................................D.20

Chain lubrication .........................................................................................D.21

Disassembling and cleaning .......................................................................D.21

Washing a chain without O-rings ................................................................D.21

Lubricating a chain without O-rings ...........................................................D.21

Shock absorber adjustment ........................................................................D.22

Shock absorber spring preload adjustment ................................................D.23

Front fork adjustment..................................................................................D.24

Steering bearing clearance adjustment ......................................................D.24

Fuel supply hose inspection .......................................................................D.25

Engine lubrication oil piping check .............................................................D.25

Exhaust system check ................................................................................D.26

Exhaust valve position check .....................................................................D.27

D.3

H02628

WRE 125

H02629

SMS 125

SMS 125

H02630

H02631

SMS 125

SETTINGS AND ADJUSTMENTS

Ed. 05-2011

D.4

H02635

1

H02636

2

H02637

3

4

5

SETTINGS AND ADJUSTMENTS

Ed. 05-2011

Saddle removal

Turn the rear xing (1) counter clockwise, remove it and extract the saddle.

Tank removal

Remove the saddle as described in the relevant paragraph.

Remove the screws (1) and the side panels.
(8 mm Allen wrench)

Remove the tank retaining screw (2).
(8 mm Allen wrench)

Release the clamp (5), close the cock (3) and disconnect the hose (4).