Husqvarna Cr 65 2012-2015 Workshop Service Manual – PDF DOWNLOAD

CR 65

Workshop Manual

CR 65

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FOREWORD, TABLE OF CONTENTS

Foreword This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical 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 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 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 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 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 specified 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".

Workshop Manual Ed. 09-2011 a.2

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FOREWORD, TABLE OF CONTENTS

CR 65

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 Reassembly............................................................................................ H Front Suspension.................................................................................................. I Rear Suspension.................................................................................................. J Brakes.................................................................................................................. L Electrical System................................................................................................. M Engine Cooling.................................................................................................... N Hydraulically Controlled Clutch............................................................................P Fuel supply...........................................................................................................S Special Tools.......................................................................................................W Tightening Torque Figures....................................................................................X Chassis and Wheels.............................................................................................Y

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

Workshop Manual Ed. 09-2011 a.3

IMPORTANT NOTICES

CR 65

Section

b

Workshop Manual Ed. 09-2011 b.1

IMPORTANT NOTICES

CR 65 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 vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The Customer bears all part replacement and labour costs needed to respect the maintenance schedule. In case of motorcycle hire the warranty becomes NULL and VOID. Notes Left and right side is determined when seated on motorcycle.

Z: number of teeth A: Austria AUS: Australia B: Belgium BR: Brazil CDN: Canada CH: Switzerland D: Germany E: Spain F: France FIN: Finland GB: Great Britain I: Italy J: Japan USA: United States of America Unless otherwise specified, data and instructions apply to all market variants.

Workshop Manual Ed. 09-2011 b.2

GENERAL INFORMATION

CR 65

Section

A

Workshop Manual Ed. 09-2011 A.1

GENERAL INFORMATION

CR 65 Engine...........................................................................................................A.3 Fuel system...................................................................................................A.3 Lubrication.....................................................................................................A.3 Cooling..........................................................................................................A.3 Ignition system..............................................................................................A.3 Kick . .............................................................................................................A.3 Primary drive.................................................................................................A.3 Gearbox.........................................................................................................A.3 Secondary drive............................................................................................A.3 Drive chain....................................................................................................A.3 Chassis..........................................................................................................A.3 Suspension....................................................................................................A.3 Brakes...........................................................................................................A.4 Wheels..........................................................................................................A.4 Tyres..............................................................................................................A.4 Overall dimensions - Weight..........................................................................A.4 Electrical components location......................................................................A.5 Capacities......................................................................................................A.5

Workshop Manual Ed. 09-2011 A.2

GENERAL INFORMATION

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

Primary drive/gearbox with oil inside the crankcase Cooling Liquid-cooling with double radiator Ignition system Spark plug type..........................................................................NGK BR8 ECM Spark plug electrode gap........................................................................0.6 mm Kick..............................................................................................................start Primary drive Drive pinion gear......................................................................................... Z 23 Sprocket ..................................................................................................... Z 75 Transmission ratio .......................................................................................3.26 Gearbox Type............................................................................. constant mesh gear type Transmission ratio 1st 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 drive Transmission sprocket . .............................................................................. Z 14 Rear sprocket.............................................................................................. Z 48 Transmission ratio .......................................................................................3.43 Drive chain Make and type...............................................................“D.I.D.” 420 - 1/2” x 1/4” Chassis Type single frame, in steel tubes with rectangular and oval section;

rear chassis in squared sectioned tubes in light alloy.

Suspension Front Type.........................................upside-down telescopic fork with advanced axle

(damping rebound and compression adjustment); Tubes.................................................................................................... ø 35 mm Wheel travel...........................................................................................220 mm Rear Type..................................... progressive “Soft Damp” with hydraulic monoshock (spring preload, rebound and compression damping adjustment) Wheel travel...........................................................................................270 mm

Workshop Manual Ed. 09-2011 A.3

GENERAL INFORMATION

CR 65 Brakes Front Type........................................................ with fixed disc “Wave” type Ø 200 mm hydraulic control and four piston fixed calliper.

Rear Type........................................................ with fixed disc “Wave” type Ø 165 mm with hydraulic control and two piston fixed calliper.

Wheels Rims Front...................................................................................in light alloy: 1.6x14” Rear....................................................................................in light alloy: 1.6x12” Tyres Front......................................... PIRELLI SCORPION MX60/100 14” 29M NHS Rear...........................................PIRELLI SCORPION MX80/100 12” 50M NHS Cold tyre pressure Front........................................................................................................ 0.8 bar Rear......................................................................................................... 0.8 bar Overall dimensions - Weight

243 mm (9.57 inch)

1130 mm (44.49 inch) 1640 mm (64.57 inch)

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

Workshop Manual Ed. 09-2011 A.4

750 mm (29,53 inch)

(11.02 inch)

280 mm

1015 mm (39.96 inch)

*770 mm (30.31 inch)

230 mm (9.06 inch)

GENERAL INFORMATION

CR 65 Electrical component location The ignition system includes the following elements: - Generator on the inner side of L.H. crankcase half cover; - Electronic ignition coil on frame RH side; - Spark plug on cylinder head; Capacities Type Fuel tank oil-fuel mixture at 3% for running-in, then at 2% Oil for mixture CASTROL XR77 Crankcase oil CASTROL POWER RACING 10W-50

Quantity 3.5 litres 500 cc (oil change)

Front fork oil

CASTROL SYNTHETIC FORK OIL - 5W

Cooling system fluid Front brake fluid Rear brake fluid Clutch fluid Drive chain lubrication Grease lubrication Electric contact protection Fillers for radiator Air filter oil Air filter cleaner

CASTROL MOTORCYCLE COOLANT 0.6 litres CASTROL RESPONSE SUPER (DOT 4) CASTROL RESPONSE SUPER (DOT 4) MINERAL OIL SAE 10 FOR HYDRAULIC CIRCUITS CASTROL CHAIN LUBE RACING CASTROL LM GREASE 2 CASTROL METAL PARTS CLEANER AREXONS LIQUID FILLER CASTROL “Foam air filter oil” CASTROL “Foam air filter cleaner”

IMPORTANT - Do not add any additives to fuel or lubricants

Workshop Manual Ed. 09-2011 A.5

MAINTENANCE

CR 65

Section

B

Workshop Manual Ed. 09-2011 B.1

MAINTENANCE

Transmission oil level check

●

Transmission oil change

●

● ●

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)

● ●

Workshop Manual Ed. 09-2011 B.2

Before the race

●

Spark plug check and/or replacement, electrode gap adjustment

Carburettor cleaning and adjustment

Once a year

Every 40 hours

After the first 5 hours

ENGINE

Every 20 hours

CR 65

MAINTENANCE

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 *

●

Before the race

Once a year

After the first 5 hours

CHASSIS

Every 20 hours

CR 65

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

●

●

●

●

Screw tightening check

●

●

Fork dust seal removal and cleaning

●

●

●

●

●

●

Steering bearing check and/or adjustment

●

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.

Workshop Manual Ed. 09-2011 B.3

MAINTENANCE

CR 65

Transmission oil level check

●

Coolant level check

●

Brake fluid level check

●

Brake shoe wear check

●

Brake operation check

●

Control cable adjustment and lubrication

Once a year

Before every race

After every cleaning

Before every use

CHECKS

● ●

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

●

Workshop Manual Ed. 09-2011 B.4

●

TROUBLESHOOTING

CR 65

Section

C

Workshop Manual Ed. 09-2011 C.1

TROUBLESHOOTING

CR 65 ENGINE Trouble

Cause

Remedy

Engine does not start or it hardly starts

Insufficient compression 1. Piston seizure 2. Connecting rod small or big end seized 3. Worn piston rings 4. Worn cylinder 5. Cylinder head loosely tightened 6. Head gasket leaking 7. Spark plug loose

Replace Replace Replace Replace Tighten Replace Tighten

Weak or no spark 1. Spark plug faulty 2. Fouled or wet spark plug 3. Spark plug electrode gap too wide 4. Ignition coil faulty 5. High-tension cables open circuit or shorted

Replace Clean or dry Adjust Replace Check

The carburettor is not receiving fuel 1. Tank cap breather clogged 2. Fuel cock clogged 3. Fuel feed pipe clogged 4. Floater valve or floaters faulty 5. Linkage is blocking floater valve

Clean Clean Clean Replace Release

Carburettor floods

1. High fuel level in bowl

2. Floater valve or floaters worn or stuck open

Replace or release

The engine stops easily

Clean Clean Adjust

1. Dirty spark plug 2. Carburettor jets clogged 3. Low idle

Engine is noisy Noise seems to come from piston

1. Too much piston-to-cylinder clearance

2. Worn piston rings or piston grooves

3. Too much carbon build-up in combustion chamber or on piston crown

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

Workshop Manual Ed. 09-2011 C.2

Adjust

Replace Replace Clean Replace Replace Replace Tighten

TROUBLESHOOTING

CR 65 Trouble

Cause

Remedy

The noise seems to come from the secondary transmission chain

1. Chain stretched or incorrectly adjusted 2. Worn transmission sprockets

Replace or adjust Replace

The clutch slides

1. Weak clutch springs 2. Worn clutch plates

Replace Replace

The clutch is tight

1. Non uniform spring load 2. Bent clutch plates

Replace Replace

The gears cannot be inserted

1. Bent or seized gearbox forks 2. Worn gear ratchets 3. Damaged shifter fork shafts

Replace Replace Replace

Gear shift pedal does not return in position

1. Weak or broken selector return spring 2. Worn shifter forks

Replace Replace

The gears are disengaged

1.

2.

3.

4.

5.

Worn sliding gear engagements Worn gear grooves Worn dog slots in gears Worn selector shaft splines Damaged shifter fork shafts

Replace Replace Replace Replace Replace

1.

Engine power lack

2.

3.

4.

5.

6.

Dirty air filter Carburettor main jet clogged or Wrong size Poor fuel quality Intake coupling loose Spark plug electrode gap too wide Insufficient compression

Clean

The engine overheats 1.

2.

3.

4.

5.

Dirty combustion chamber and/or piston crown with carbon deposits Insufficient oil in crankcase or use of wrong oil Obstructions blocking air flow on radiator Cylinder head gasket leaking Clutch slips

Clean or replace Replace Tighten Adjust Identify cause Clean Top up or change Clean Replace Adjust

Workshop Manual Ed. 09-2011 C.3

TROUBLESHOOTING

CR 65 CHASSIS Trouble The handlebar is hard to turn

Cause Remedy Inflate 1. Tyre pressure insufficient 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.

2.

3.

4.

5.

Bent fork legs Bent front wheel axle Bent/broken chassis Bent front wheel rim Worn front wheel bearings

Replace Replace Replace Replace Replace

Shock absorption is too hard

1.

2.

3.

4.

Exceeding oil quantity in fork legs Fork oil viscosity too high Overinflated tyres Improperly set rear shock absorber

Drain the exceeding oil Change Deflate Adjust

Shock absorption is too soft

1.

2.

3.

4.

5.

Insufficient oil quantity in fork legs Fork oil viscosity too low Weak fork springs Weak rear shock absorber spring Improperly set rear shock absorber

Top up Change Replace Replace Adjust

Wheel (front and rear) vibrates

1.

2.

3.

4.

5.

6.

7.

Bent wheel rim Worn wheel hub bearings Incorrect spoke tension Wheel axle nut loose Worn rear swinging arm bearings Improperly adjusted chain tensioners Improperly balanced wheel

Replace Replace Adjust Tighten Replace Adjust Balance

Rear suspension is noisy

1. Shock absorber worn ball joints 2. Faulty shock absorber

Replace Replace

Insufficient braking (front and rear)

1.

2.

3.

4.

5.

6.

Bleed Top up Replace Replace Adjust Change fluid

Air presence in braking system circuit Insufficient fluid in tank Worn brake pad and/or disc Damaged disc Improperly adjusted brake pedal Water in brake system

Workshop Manual Ed. 09-2011 C.4

TROUBLESHOOTING

CR 65 ELECTRICAL SYSTEM (see also Section M) Trouble

Cause

Remedy

The spark plug gets dirty easily

1.

2.

3.

4.

5.

Spark plug electrodes overheat

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

Mixture too rich Adjust carburettor Dirty air filter Clean Worn piston rings Replace Worn piston or cylinder liner Replace Spark plug featuring a too high heat rating Replace with recommended spark plug

Workshop Manual Ed. 09-2011 C.5

SETTINGS AND ADJUSTMENTS

CR 65

Section

D

Workshop Manual Ed. 09-2011 D.1

SETTINGS AND ADJUSTMENTS

CR 65 Saddle removal.............................................................................................D.4 Tank removal.................................................................................................D.4 Remove the chain/sprocket cover protection casing.....................................D.5 Throttle cable adjustment..............................................................................D.5 Carburettor adjustment..................................................................................D.6 Idle adjustment..............................................................................................D.6 Front brake fluid level check . .......................................................................D.6 Clutch oil level check.....................................................................................D.7 Front brake lever adjustment.........................................................................D.8 Lever distance adjustment............................................................................D.8 Clutch distance adjustment...........................................................................D.8 Rear brake pedal position adjustment ..........................................................D.9 Rear brake pedal free play adjustment ........................................................D.9 Rear brake fluid level check........................................................................D.10 Oil level check.............................................................................................D.11 Oil replacement...........................................................................................D.11 Coolant level check.....................................................................................D.12 Coolant replacement...................................................................................D.12 Air filter cleaning and check .......................................................................D.13 Chain adjustment .......................................................................................D.14 Chain lubrication..........................................................................................D.14 Removal and cleaning.................................................................................D.14 Chain cleaning.............................................................................................D.14 Chain lubrication..........................................................................................D.14 Fork adjustment . ........................................................................................D.15 Rebound damping adjustment (RH fork leg)...............................................D.15 Compression damping adjustment (LH fork leg).........................................D.15 Fork position adjustment.............................................................................D.16 Rear shock absorber adjustment................................................................D.16 Shock absorber spring preload adjustment.................................................D.17 Shock absorber hydraulic damping adjustment..........................................D.18 Steering bearing clearance adjustment.......................................................D.19 Handlebar position change..........................................................................D.19 Tank supply and breather pipe check..........................................................D.21 Exhaust system check.................................................................................D.21 Sound deadening material replacement......................................................D.22

Workshop Manual Ed. 09-2011 D.2

SETTINGS AND ADJUSTMENTS

CR 65

CR 65

Workshop Manual Ed. 09-2011 D.3

SETTINGS AND ADJUSTMENTS

CR 65 Saddle removal Turn the rear pin (1) counterclockwise.

Release the saddle (2) from the front retaining screw pin.

1

2

Tank removal Remove the saddle as described in the relevant paragraph.

Close the fuel cock (2) and loosen the clamp (3) on the hose running to the carburettor. Detach hose (4) from carburettor making sure to drain any fuel in the hose into a container.

2 3

Remove the side panels as described in section E.

4

Slide the breather hose (7) out of the steering tube.

Remove the retaining screw (8) and then the tank (9).

7 8

Workshop Manual Ed. 09-2011 D.4

SETTINGS AND ADJUSTMENTS

CR 65

9

4

Remove the chain/sprocket cover protection casing

1

Cut the ties (1) and remove the casing (2).

Loosen the 3 screws (3) that fasten the sprocket cover to the LH casing (4) and remove the protection.

2

3

Throttle cable adjustment

2 mm

To check the correct adjustment of the throttle control cable, operate as follows: - Turn throttle control twistgrip (1) and make sure it has about 2 mm free play;

1

3

2

- 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 handlebar 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.

4

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

Workshop Manual Ed. 09-2011 D.5

SETTINGS AND ADJUSTMENTS

CR 65

1

Carburettor adjustment Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: - turn the idle speed adjuster screw (1) located on the left-hand side of the vehicle, until setting idle RPM quite high (turn clockwise to increase the speed and counter clockwise to reduce the speed).

- 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 adjustment Adjust the carburettor with warm engine and with the throttle control in closed position. Proceed as follows: - Turn the idle speed adjuster screw (1) located on the left-hand side of the vehicle, until setting idle RPM as required (turn clockwise to increase the speed and counter clockwise to reduce it).

2

Front brake fluid level check

1

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);

2

- 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.

3

Workshop Manual Ed. 09-2011 D.6

SETTINGS AND ADJUSTMENTS

CR 65 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").

3 mm

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

1

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);

2

- 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).

3

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.

Workshop Manual Ed. 09-2011 D.7

SETTINGS AND ADJUSTMENTS

CR 65 Front brake lever adjustment Position adjustment Loosen the screws (2) to adjust the lever (1) position.

When finished, tighten the screws (2) again.

1

2

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

B

A

3

Clutch lever adjustment Lever distance adjustment To 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.

A B

4

5

Workshop Manual Ed. 09-2011 D.8

SETTINGS AND ADJUSTMENTS

CR 65 Rear brake pedal position adjustment

3

2

A

The position of the rear brake pedal with respect to the footrest may be adjusted according to individual needs.

For adjusting, proceed as follows: - Loosen the screw (1).

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

1 Rear brake pedal free play adjustment The rear brake pedal (3) should have a free play (B) (5 mm) before the brakes begin to bite.

3

0.2 in.

5 mm

B

5

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.

4

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).

Workshop Manual Ed. 09-2011 D.9

SETTINGS AND ADJUSTMENTS

CR 65 Rear brake fluid level check

2

The fluid level that can be seen through the inspection window (1) must be above the minimum mark on the master cylinder tank.

To restore the level loosen the two screws (2), remove the cover (3), and top-up with oil type specified in the "LUBRICATION AND SUPPLIES" table.

3

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

1

MIN

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).

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 call a doctor if your eyes were exposed.

Workshop Manual Ed. 09-2011 D.10

SETTINGS AND ADJUSTMENTS

CR 65 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.

1

Oil replacement Be careful not to touch hot engine oil.

2

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.

3

Workshop Manual Ed. 09-2011 D.11

SETTINGS AND ADJUSTMENTS

CR 65 Coolant level check Check level (1) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 0.39 in. above the cells.

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 replacement Place a vessel on the RH side of the cylinder, under the screw (1).

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.

2

A

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).

A

B

B

Workshop Manual Ed. 09-2011 D.12

SETTINGS AND ADJUSTMENTS

CR 65 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).

2 1

3 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.

4

5

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.

Workshop Manual Ed. 09-2011 D.13

SETTINGS AND ADJUSTMENTS

CR 65 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 ø drill rod (A) on the upper chain guide.

Adjust the chain tension so that the drill rod passes freely without excessively loosening the chain.

A

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 tightening 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).

3 1

4

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.

2

2 4

3

Workshop Manual Ed. 09-2011 D.14

SETTINGS AND ADJUSTMENTS

CR 65 Chain lubrication Lubricate the chain following these instructions.

Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets.

Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication. 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.

3 2 1

Chain cleaning Wash 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 adjustment The 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 10Âą1 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 10Âą1 CLICKS. Turn clockwise to increase the damping and vice versa.

Rebound damping (RH leg) Standard

10 clicks counterclockwise from end of travel

Compression damping (LH leg) Standard

10 clicks counterclockwise from end of travel

Workshop Manual Ed. 09-2011 D.15

SETTINGS AND ADJUSTMENTS

CR 65 Fork position adjustment - Loosen the two screws (1) onto bottom yoke.

- Loosen the steering head screw (2).

- Adjust one fork leg at a time.

2

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.

1

A B C

D

Shock absorber adjustment The 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.

B

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.

A C

- 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 25รท30 mm (0.98 รท 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 60รท70 mm (2.36 รท 2.76 in).

B: silencer retaining screw axle C: rear wheel axle height

Workshop Manual Ed. 09-2011 D.16

SETTINGS AND ADJUSTMENTS

CR 65 Shock absorber spring preload adjustment

4

Proceed as follows: 1. Remove the side panels as described in Section "E".

(4) and remove the two lower screws (5) 2. Loosen the two upper screws that fasten the rear chassis to the frame.

3. Remove the clamp (6) of the tube that connects the filter box to the carburettor.

4. Remove the retaining screw (7) that fastens the silencer to the rear chassis.

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

5

6

Be careful not to touch hot exhaust pipe while adjusting the shock absorber.

7

A

1 2 3

The standard length of the pre-loaded spring is as follows: A= 217 Âą 1.5 mm

Workshop Manual Ed. 09-2011 D.17

SETTINGS AND ADJUSTMENTS

CR 65 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 reaching 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.

1

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

B) COMPRESSION - Standard setting: 1 turn and ½ (from fully closed) To reset the standard setting, turn upper adjuster screw clockwise (2) until reaching 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.

2

Shock absorber spring (3) STANDARD K=4.2 daN/mm

Spring preload (shock absorber ring nut) Standard

spring length when in its seat 217 mm ±1.5

Rebound damping (lower screw) Standard

2 turns counterclockwise from end of travel

Compression damping (upper screw)

3

Standard

Workshop Manual Ed. 09-2011 D.18

1 turn and ½ counterclockwise from end of travel

SETTINGS AND ADJUSTMENTS

CR 65 Steering bearing clearance adjustment For safety reasons, the steering should always be adjusted so that the handlebar turns freely and without play. To check steering adjustment, set a stand or a block under the engine and see that the front wheel is lifted from the ground. Press lightly on the handlebar grips to cause the front end to rotate; 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.

2

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

3

Handlebar position change

1

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

2

1

- 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

Workshop Manual Ed. 09-2011 D.19

SETTINGS AND ADJUSTMENTS

CR 65 - Afterwards remove the lower ones (3) by loosening the relevant retaining screws (4).

4

3

- 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.).

5

- 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 routing 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.

1

- 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.

2

3 A 4

Workshop Manual Ed. 09-2011 D.20

A

SETTINGS AND ADJUSTMENTS

CR 65 Tank supply and breather pipe check Make sure the pipes (1) and (2) do not feature any leakage, cut, or evident cracks, and in case replace them.

1

Replace the supply pipe (1) as described in section "E".

2

Exhaust system check

1

Remove exhaust system components as described in Section "E". Ensure that pipe (1) and silencer (2) do not show any sign of failure or damage: replace if cracked or damaged.

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

2

Workshop Manual Ed. 09-2011 D.21

SETTINGS AND ADJUSTMENTS

CR 65 Sound deadening material replacement Remove the silencer (1) as described in the relevant paragraph and fasten it on a suitable support (vice provided with aluminium protections) having care not to deform the pipe.

1

3

Remove screws (2) that retain the rear end cap (3) and remove it from the silencer body.

2

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

4

5

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.

Workshop Manual Ed. 09-2011 D.22

SETTINGS AND ADJUSTMENTS

CR 65 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.

2

6

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

Workshop Manual Ed. 09-2011 D.23

GENERAL PROCEDURES

CR 65

Section

E

Workshop Manual Ed. 09-2011 E.1

GENERAL PROCEDURES

CR 65 Foreword.......................................................................................................E.3 Number holder removal ................................................................................E.4 Front mudguard removal ..............................................................................E.4 Saddle removal.............................................................................................E.5 Side panel removal . .....................................................................................E.5 Rear chassis with rear mudguard and air filter removal .................................E.6 Exhaust system removal ..............................................................................E.7 Fuel tank removal .........................................................................................E.9 Carburettor removal from the engine..........................................................E.10 Spark plug cap removal . ............................................................................E.10 Radiator removal.........................................................................................E.10 Swinging arm removal ................................................................................E.12 Secondary drive chain removal...................................................................E.13 Clutch actuator removal .............................................................................E.13 Generator cable removal ............................................................................E.14 Engine removal from the chassis ..............................................................E.14

Workshop Manual Ed. 09-2011 E.2

GENERAL PROCEDURES

CR 65 Foreword This section describes the operations preliminary to engine removal.

Please note that, in order to gain access to certain motorcycle components (rear shock absorber, electrical parts, wiring, etc.), it may be necessary to partially remove some parts.

RIGHT-HAND SIDE

LEFT-HAND SIDE

Workshop Manual Ed. 09-2011 E.3

GENERAL PROCEDURES

CR 65 Number holder removal - Loosen the screw (1) with an 8 mm wrench and lift the Number holder to remove it.

1

- Widen the cable ring (2) to release the engine stop cable (4) and the front brake transmission (3).

3 2 4

Front mudguard removal - Using an 8 mm wrench, loosen the four screws (1), and remove mudguard (2).

1

2

Workshop Manual Ed. 09-2011 E.4

GENERAL PROCEDURES

CR 65 Saddle removal - Turn the rear pin (1) counterclockwise.

1

- Release the saddle (2) from the front retaining screw pin.

2

2

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).

1

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

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

3

3

3

4 Workshop Manual Ed. 09-2011 E.5

GENERAL PROCEDURES

CR 65 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).

3 1

2

- 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.

4

4

5

- 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.

Workshop Manual Ed. 09-2011 E.6

GENERAL PROCEDURES

CR 65 Exhaust system removal

Key 1 Expansion pipe/silencer 2 Gasket 3 Springs 4 Elastic supports 8 Coupling 9 Silencer 10 Silencer support

10

- 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).

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

9 Workshop Manual Ed. 09-2011 E.7

GENERAL PROCEDURES

CR 65 - Remove the silencer (9) by sliding it from the rear side as shown in the figure.

Pay attention to the rubber connection coupling (8).

9

8

- Remove the springs (3) from the silencer (1).

3

1

- Use an 8 mm ring wrench to remove the screw (7) from the elastic support fastened on the chassis.

7

1

- Remove the silencer (1).

Workshop Manual Ed. 09-2011 E.8

GENERAL PROCEDURES

CR 65 - Check conditions of gasket (2) and if damaged replace it.

2

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

1

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

2

- 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.

3

4

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

5

Workshop Manual Ed. 09-2011 E.9

GENERAL PROCEDURES

CR 65 Carburettor removal from the engine - Loosen the tie (1) and remove the carburettor from the intake fitting.

1

Spark plug cap removal - Take off the spark plug cap (1).

1

Radiator removal - Remove the grids from the two radiators (1) releasing the pins from the holes as shown in the figure.

1

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

2

Workshop Manual Ed. 09-2011 E.10

GENERAL PROCEDURES

CR 65 - 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.

4

7

- 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).

5

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

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

3

To remove the RH radiator proceed as follows: - Loosen clamp (1) that fastens the connection pipe (2) to the water pump.

2

1 Workshop Manual Ed. 09-2011 E.11

GENERAL PROCEDURES

CR 65 - Release the radiator breather hose (3) from the two chassis connection rubber clamps (4).

3

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.

5

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.

6

6

Swinging arm removal

1

2

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

Workshop Manual Ed. 09-2011 E.12

GENERAL PROCEDURES

CR 65 3

A

- 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.

B

4

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

1

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

2

3 1

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.

2

Workshop Manual Ed. 09-2011 E.13

GENERAL PROCEDURES

CR 65 Generator cable disconnection - Cut the tie (1) that retains the cables against the chassis. Disconnect the generator electric cable connector (2).

2

1

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.

1

Workshop Manual Ed. 09-2011 E.14

ENGINE DISASSEMBLY

CR 65

Section

F

Workshop Manual Ed. 09-2011 F.1

ENGINE DISASSEMBLY

CR 65 Preparation.....................................................................................................F.3 Gearbox oil drainage procedure.....................................................................F.3 Cylinder head, cylinder and piston removal...................................................F.3 Water pump disassembly ..............................................................................F.4 Clutch cover removal......................................................................................F.5 Clutch disassembly........................................................................................F.5 Primary drive sprocket removal......................................................................F.6 Kick start pedal shaft removal........................................................................F.7 Gearbox control shaft and selector plate removal..........................................F.7 Intake flange and reed valve removal............................................................F.8 Starting system disassembly..........................................................................F.8 Chain sprocket removal..................................................................................F.9 Splitting the crankcase...................................................................................F.9 Gearbox control and shaft removal................................................................F.9 Process........................................................................................................F.10 Crankshaft removal from casing...................................................................F.10

Workshop Manual Ed. 09-2011 F.2

ENGINE DISASSEMBLY

CR 65 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.

1

Cylinder head, cylinder and piston removal – Loosen the spark plug.

– Remove all cylinder head screws (2) and the head itself.

2

– – – –

3 4

6

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.

5

Workshop Manual Ed. 09-2011 F.3

ENGINE DISASSEMBLY

CR 65 – Cover the crankcase with a clean cloth and place the piston on a wood support.

– 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.

1

A

1

B

– 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 possible to slide it out along with the clutch cover by loosening the cover screws.

Workshop Manual Ed. 09-2011 F.4

ENGINE DISASSEMBLY

CR 65 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)).

2

– Remove both centring bushings.

– Remove the spring (2) of the starting coupling, the thrust washer (3) and the thrust bearing (4).

3 4

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

5

1

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

– Remove the hexagonal-head screw.

Workshop Manual Ed. 09-2011 F.5

ENGINE DISASSEMBLY

CR 65 – Remove the plate pack (2) from the clutch housing.

2

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 supporting bushing (3) and the thrust washer (4) placed behind.

– Remove the starting idle gear (5).

5

4

3

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 SPROCKET, THE PRIMARY DRIVE MUST NOT BE BLOCKED WITH A SECTOR GEAR OR ALIKE. THAT WOULD DAMAGE THE CRANKSHAFT.

6

– 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.

Workshop Manual Ed. 09-2011 F.6

ENGINE DISASSEMBLY

CR 65 1

2

3

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.

4

5

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

Workshop Manual Ed. 09-2011 F.7

ENGINE DISASSEMBLY

CR 65 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.

1

Ignition system disassembly – Loosen the 3 screws of the ignition cover and remove the latter (1).

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.

2

3

Workshop Manual Ed. 09-2011 F.8

4

ENGINE DISASSEMBLY

CR 65 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.

1

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 SCREWDRIVER 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.

3

– – – – –

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 together with the gearbox forks (5).

– Remove the selector drum (6) with the relevant shim (if any) from the casing.

2

4

4

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.

5 5 6

5

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.

Workshop Manual Ed. 09-2011 F.9

ENGINE DISASSEMBLY

CR 65 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.

1

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 100°C. – 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.

Workshop Manual Ed. 09-2011 F.10

ENGINE OVERHAUL

CR 65

Section

G

Workshop Manual Ed. 09-2011 G.1

ENGINE OVERHAUL

CR 65 Engine crankcase (crankcase half)...............................................................G.3 Actions on left crankcase half........................................................................G.4 Actions on right crankcase half.....................................................................G.5 Crankshaft measurement..............................................................................G.6 Actions on clutch cover.................................................................................G.6 Water pump disassembly and inspection......................................................G.7 Piston check..................................................................................................G.8 Piston ring gap measurement.......................................................................G.8 Piston and cylinder measurement, piston assembly clearance determination..........................................................................G.8 Reed valve, intake flange..............................................................................G.9 Gearbox control shaft disassembly.............................................................G.10 Gearbox control – check for component wear.............................................G.10 Gearbox control shaft pre-assembly...........................................................G.10 Clutch – check for component wear............................................................ G.11 Plate pack pre-assembly............................................................................. G.11 Kick start pedal shaft pre-assembly............................................................G.12 Gearbox shafts – check for component wear..............................................G.12 Input shaft assembly...................................................................................G.13 Output shaft assembly.................................................................................G.13

Workshop Manual Ed. 09-2011 G.2

ENGINE OVERHAUL

CR 65 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 crankcase 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.

Workshop Manual Ed. 09-2011 G.3

ENGINE OVERHAUL

CR 65 Actions on left crankcase half Remove the oil seals and heat the crankcase half on an electric plate up to 150 °C.

3 2

1

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 damaged 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.

4

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 Ø 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.

3

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.

6

5

Gearbox control shaft oil seal (7).

From the outer side, force the new oil seal in with the sealing lip inwards.

7

S

After crankcase half has cooled down check that all bearings are properly positioned in their seats.

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

Workshop Manual Ed. 09-2011 G.4

ENGINE OVERHAUL

CR 65 Actions on right crankcase half Remove the oil seals and heat the crankcase half on an electric plate up to 150 °C.

2 6

1

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 damaged 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.

5

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.

3

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

2

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.

8 7

9

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.

Workshop Manual Ed. 09-2011 G.5

ENGINE OVERHAUL

CR 65 S

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

Crankshaft measurement Always check the drive shaft axes misalignment when reusing the crankshaft.

Max. drive shaft axes misalignment 0.05 mm Check the radial clearance to the connecting rod big end bearing.

Max. radial clearance 0.03 mm

Actions on clutch cover Kick 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).

1

Workshop Manual Ed. 09-2011 G.6

ENGINE OVERHAUL

CR 65 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.

1

– Push the water pump shaft (2) inside together with the ball bearings to remove it from the clutch cover.

2

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 IMPELLER COULD LOOSEN.

3

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

Workshop Manual Ed. 09-2011 G.7

ENGINE OVERHAUL

CR 65 Piston check Check what follows when reusing a piston: 1. Check for any dent or seizure on the piston sliding surface (you can use a fine grain abrasive stone to remove light seizure signs).

2. Piston ring groove: The piston ring must not get stuck in the groove. To clean the groove use an old piston ring or abrasive paper (grain 400).

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.

10mm x

x

y

50mm

y

Piston and cylinder measurement, and piston assembly clearance determination.

– 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 necessary to replace both cylinder and piston.

Workshop Manual Ed. 09-2011 G.8

ENGINE OVERHAUL

CR 65 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.

Workshop Manual Ed. 09-2011 G.9

ENGINE OVERHAUL

CR 65 1 2

2

1

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 compression spring (5) from the gearbox control shaft (6).

– Remove the compression spring (5) by moving the sliding plate (3) and removing it from the selector (4).

Gearbox control – component wear check Sliding plate (3) Check wear on engagement points on the shaped selector plate.

Check the sliding plate return surface wear (replace if too much notched).

4 6

3

Selector (4) Check wear on engagement points on the shaped selector plate.

Check the guiding pin fixed seat and wear.

5

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

7 9

11

12 8

10 12

11

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

7

7

12 10

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).

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.

Workshop Manual Ed. 09-2011 G.10

ENGINE OVERHAUL

CR 65 6

1 2 5

7

LOXEAL 86-54 LOCTITE 243

A

3

4

Clutch – check for component wear Check for component wear: Thrust bearing (1) Clutch springs (2) Minimum length 25 mm (when new 27 mm), if necessary replace all 6 springs.

B

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.

Workshop Manual Ed. 09-2011 G.11

ENGINE OVERHAUL

CR 65

4

5

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.

6 7

B

Gearbox shafts – component wear check – Fasten the input and output shafts in the vice (use protection 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.

1

2

Workshop Manual Ed. 09-2011 G.12

3

4

5

6

7

ENGINE OVERHAUL

CR 65 Input shaft assembly – Fasten the input shaft with the splined end down in the vice (use protection jaws).

– Properly oil all components before assembly.

– Insert the 5th neutral gear (1) with the front couplings upwards, and fit the circlip (2) with the sharp edge upwards.

– Insert the 3rd/4th sliding gear pair (3) with the smaller gear up on the input shaft, and fit the circlip (4) with sharp edge upwards.

– Fit the 6th neutral gear (5) with the front couplings down, and the 2nd fixed gear (6) with the milled part downwards.

– Fit the thrust washer (7).

– Then check that all gears move freely.

11 10

9

8

7

6

5

4

3

2

1

Output shaft assembly – Fasten the output shaft with the splined end down in the vice (use protection jaws).

– Properly oil all components before assembly.

– Insert the 2nd neutral gear (1) with the teeth bevelling downwards, and fit the circlip (2) with the sharp edge upwards.

– Insert the 6th sliding gear (3) with the fork slot upwards, and fit the circlip (4) with the sharp edge downwards.

– Insert the 3rd neutral gear (5) with the fork slot upwards, and the 4th neutral gear (6) with the fork slot downwards.

– Fit the circlip (7) with the sharp edge upwards.

– Fit the 5th sliding gear (8) with the fork slot downwards.

– Insert the needle roller bearing (9) on the shaft.

– Fit the 1st neutral gear (10) with the slot downwards and then the thrust washer (11).

– Then check that all gears move freely.

Workshop Manual Ed. 09-2011 G.13

ENGINE REASSEMBLY

CR 65

Section

H

Workshop Manual Ed. 09-2011 H.1

ENGINE REASSEMBLY

CR 65 Inserting the crankshaft in the engine casing............................................... H.3 Refitting the gearbox shafts and the gearbox control .................................. H.3 Crankcase halves coupling.......................................................................... H.4 Refitting the kick start pedal shaft ............................................................... H.4 Refitting the selector plate and the gearbox control shaft............................ H.5 Clutch assembly........................................................................................... H.5 Refitting the primary drive sprocket.............................................................. H.6 Refitting the starting coupling, and kick start pedal shaft pre-load............... H.6 Refitting the clutch cover.............................................................................. H.7 Refitting the chain sprocket.......................................................................... H.7 Refitting reed valve and intake flange.......................................................... H.8 Refitting the ignition system and adjusting the fixed spark advance............ H.9 Cylinder head installation........................................................................... H.10 Refitting the kick start pedal ...................................................................... H.10 Refitting the ignition cover.......................................................................... H.10 Gearbox oil filling procedure....................................................................... H.11

Workshop Manual Ed. 09-2011 H.2

ENGINE REASSEMBLY

CR 65 Inserting the crankshaft in the engine casing – Fasten the right crankcase half onto the installation stand.

– Grease the crankshaft oil seal and oil the crankshaft ball bearing.

– Fit the crankshaft installation tool with the relevant bushing (1) and insert the crankshaft fully home.

UPON CRANKSHAFT INSERTION THE CONNECTING ROD MUST BE FACED TO THE CYLINDER.

1

Refitting the gearbox shafts and control – Keep the input and output shafts in your hand as shown in the picture, and insert the two shafts together in the relevant seats.

CHECK THE SEAT OF THE OUTPUT SHAFT LOWER THRUST WASHER. THE UPPER GEAR PAIR MUST TURN ON THE SAME AXIAL PLANE.

4 2

– USED GEARBOX FORKS MUST BE REFITTED IN THE SAME SLIDING GEAR THEY WERE BEFORE. FOR THIS REASON, UPON REASSEMBLY PAY ATTENTION TO THE SIGNS MARKED DURING DISASSEMBLY. – MAKE SURE THE BUSHINGS DO NOT FALL FROM THE GEARBOX FORKS.

3

5

– Engage the gearbox fork with the smallest round opening (2) in the input shaft sliding gear.

– Use a screwdriver to slightly lift up the lower sliding gear of the output shaft and engage the gearbox fork (3).

– Engage the last gearbox fork (4) in the output shaft upper sliding gear.

– Grease and fasten the shims (8) on the selector drum.

– Grease the selector drum (5) and insert it in the engine casing.

– Engage the gearbox forks in the selector drum.

WARNING: The fork guiding rods are loaded by means of a spring, and the lower springs should be lightly greased and fastened to the guiding rods.

6 7 8

– Insert the fork guiding rod (6) into input shaft the gearbox fork and the long fork guiding rod (7) into the output shaft gearbox forks.

– Insert the fork guiding rods fully inside the casing holes.

WARNING: The gearbox shafts must now be easy to be turned.

8 8

Workshop Manual Ed. 09-2011 H.3

ENGINE REASSEMBLY

CR 65 Crankcase halves coupling – Remove the engine retainers on the installation stand.

– Fit the two centring bushings in the right crankcase half.

– Grease the oil seal of the input and output shafts.

– The thrust washer 1 must not be fitted on the input shaft.

– Smear some grease on the casing sealing surface and fit a new gasket.

– Place the left crankcase half by contemporarily turning the gearbox shafts.

– Grease the threads and the bearing surface of the casing screw heads and fit the screws.

– The 4 screws in the ignition side casing must be the first to be tightened following a cross pattern. Tightening torque 10 Nm. – Tighten the other screws to 10 Nm and make sure all shafts move freely.

– Fasten the engine into the installation stand.

1

M6x40 M6x45

M6x45

M6x30

M6x45 M6x45 M6x30

M6x30

– After tightening the casing screws check the axial clearance of the selector drum. The selector drum axial clearance must be of 0.30 - 0.50 mm. The axial clearance can be compensated using shims.

Refitting the kick start pedal shaft – Insert the pre-assembled kick start pedal shaft (2) in the casing hole and fit the kick start pedal spring into the prong (A) in the casing.

– Degrease the thread of the two bolts (3) and smear some Loxeal 24-18. Fasten the stopping plate with the two M6x20 CH8 bolts to the engine casing and tighten them to 12 Nm. – Check that the starting gear moves freely.

2

A

3

Workshop Manual Ed. 09-2011 H.4

ENGINE REASSEMBLY

CR 65 3

A

Refitting the selector plate and the gearbox control shaft – Place the selector spring (1) as shown in the engine casing picture.

– Fit the selector lever (2) with the roller faced to the casing and the circlip (3) with the sharp edge upwards.

– Engage the selector spring to the casing prong A.

1 2 – Push the selector lever back and fit the selector on its drum.

– Degrease the screw thread (4), smear the thread with Loxeal 24-18 and fasten the selector plate to 14 Nm. – Grease the gearbox control shaft oil seal.

– Grease the pre-assembled gearbox control shaft and carefully insert it in the engine casing. Push the sliding plate back and insert the gearbox control shaft fully inside the engine casing.

– Fit the gear shift pedal and insert, in sequence, all gears by contemporarily turning the input shaft. Afterwards remove the gear shift pedal again.

4

5

7

Clutch reassembly – Fit the idle gear (5) with the beat faced to the casing on the supporting pin.

– Insert the thrust washer (6) and the greased supporting bushing (7) onto the input shaft.

– Insert the clutch housing and the thrust washer (17.2x30x1.5 mm) on the input shaft.

6 – Fit the pre-assembled plate pack.

– Smear some Loxeal 86-54 in the screw thread and fit the screw with the Belleville washer (see the assembly diagram at page G.10).

– Place the clutch retainer using the suitable wrench and tighten the screw to 50-52 Nm.

Workshop Manual Ed. 09-2011 H.5

ENGINE REASSEMBLY

CR 65 Refitting the primary drive sprocket WARNING: Before fitting the primary drive sprocket it is necessary to degrease the cone.

– Degrease the crankshaft thread and smear some Loxeal 100 HSP. – Fit a new thrust washer and the hexagon nut.

– Place the retaining tool for the primary drive sprocket and tighten the hexagon nut to 100 Nm. – Remove the retaining tool.

Refitting the starting coupling, kick start pedal pre-load – Fit the starting coupling (1) as shown in the kick start pedal shaft picture.

– Pre-load the kick start pedal shaft counterclockwise and engage the starting coupling on the stopping plate (a high pre-load is not necessary).

– Oil the sliding points, fit the thrust washer (2) and the spring (3) of the starting coupling with the small diameter faced to the coupling.

Workshop Manual Ed. 09-2011 H.6

ENGINE REASSEMBLY

CR 65 Refitting the clutch cover – Make sure that both centring bushings are fitted in the engine casing.

– Smear some grease on the casing sealing surface and fit a new clutch cover gasket.

– Insert the thrust bearing 1 in the spring retaining plate.

– Grease all clutch cover oil seals.

1

– Grease and fasten the spring (A) in the water pump shaft (B).

– Align the crankshaft and the water pump shaft.

B A

UPON CLUTCH COVER REASSEMBLY MAKE SURE THE CRANKSHAFT PLANE POINT ENGAGES IN THE RELEVANT GROOVE OF THE WATER PUMP SHAFT. IF NECESSARY SLIGHTLY TURN THE CRANKSHAFT.

M6x25

M6x25

M6x30 M6x30

– Position the clutch cover.

– Insert all screws in the clutch cover and tighten them to 10 Nm (see diagram for screw length).

– Check that the kick start pedal shaft moves freely.

M6x25 M6x25

2

M6x25

Refitting the chain sprocket – Oil the O-ring and fit it on the output shaft.

– Push the spacing bushing on it so that the O-ring places in the correct position.

– Fit the chain sprocket 2 with the beat faced to the output shaft casing and fasten it with the circlip 3 (sharp edge outwards).

3

Workshop Manual Ed. 09-2011 H.7

ENGINE REASSEMBLY

CR 65 Refitting reed valve and intake flange – Insert the reed valve with a new gasket in the engine casing, fit the intake flange and fasten by means of 4 screws.

– Fit the two remaining flanged screws on the cylinder base and tighten the 4 flanged screws to 18-20 Nm. – Screw the exhaust fitting and the gasket to the cylinder.

Workshop Manual Ed. 09-2011 H.8

ENGINE REASSEMBLY

CR 65 Refitting the ignition system and adjusting the fixed spark advance – Smear some Loxeal 24-18 on the three socket head screws thread and fasten the stator (1) without tightening.

– Smear some silicone in the cable ring and fit it in the relevant opening on the casing.

1

– Insert the key in the crankshaft.

– Fit the rotor on the crankshaft and mount the elastic washer with flanged nut.

– Insert the wrench (2) in the two holes and tighten the flanged nut to 60 Nm.

2

altezza cilindro

– Move the piston to the L.D.C. and place the adjusting gauge on the cylinder upper edge.

– Now the internal rotor must be turned counterclockwise until the piston upper edge touches the adjusting gauge (see sketch).

accensione

– Now turn the stator so that the two markings 3 match.

BEFORE ADJUSTING THE FIXED SPARK ADVANCE IT IS NECESSARY TO CORRECTLY ADJUST DIMENSION “X”.

3

– Smear some Loxeal 24-18 on the 3 socket head screws of the stator and tighten them to 8 Nm. – Check again the distance between the piston upper edge and the cylinder upper edge using the adjusting gauge; if necessary, adjust it by turning the stator accordingly.

Workshop Manual Ed. 09-2011 H.9

ENGINE REASSEMBLY

CR 65 Cylinder head installation – Clean the cylinder and cylinder head sealing surfaces, and fit the O-rings (1) in the relevant grooves (in case smear with some grease).

– Remove both centring bushings (2).

1

2

2

– Position the cylinder head with the water fitting back (intake side).

– Fit the cylinder head screws with the new copper sealing rings, and tighten them in two steps: first start them without tightening, then tighten definitively to the preset torque of 18 Nm. – Screw the spark plug.

– Fit the water hose (3) and fasten it with the two clamps.

3

Refitting the kick start pedal – Screw the kick start pedal (4) as shown for the kick start pedal shaft.

4

Refitting the ignition cover – Refit the cover.

– Fit the gear shift pedal in the correct position on the gearbox control shaft, and fasten it with the retaining screw.

Workshop Manual Ed. 09-2011 H.10

ENGINE REASSEMBLY

CR 65 Gearbox oil filling procedure – Screw the gearbox breather pipe to the engine casing.

– Screw the gearbox oil bleeding screw (1) with its new sealing ring, and tighten to 12 Nm. – Remove the oil filling screw from the clutch cover and fill in 0.50 l of gearbox oil.

– Refit the oil filling screw.

1

Workshop Manual Ed. 09-2011 H.11

FRONT SUSPENSION

CR 65

Section

I

Workshop Manual Ed. 09-2011 I.1

FRONT SUSPENSION

CR 65 Front suspension........................................................................................... I.3 Removing front fork....................................................................................... I.4 Fork spring features...................................................................................... I.5 Fork oil........................................................................................................... I.5 Cleaning the fork legs dust seals.................................................................. I.6

Workshop Manual Ed. 09-2011 I.2

FRONT SUSPENSION

CR 65

CR 65

Front suspension Upside-down hydraulic fork with advanced axle (compression and rebound damping adjustment) with ø 35 mm legs.

The wheel travel on the forks axle is of 220 mm.

Workshop Manual Ed. 09-2011 I.3

FRONT SUSPENSION

CR 65 Removing front fork Measure height "A" (it will need to be restored to original value on assembly). Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows: A

- Release the front brake hose and the engine stop cable from the hose ring (1) inside the Number holder.

1

- Release the front brake hose from the U-bolt (2) that fastens the hose to the left fork leg protection;

2

Workshop Manual Ed. 09-2011 I.4

FRONT SUSPENSION

CR 65 - Remove the brake calliper from the L.H. fork leg loosening the two retaining screws (2); - Remove the front wheel as described in Section "Y";

2

- Loosen the bolts (3) that secure the fork legs to steering head and bottom yoke; - Remove the fork legs.

3

After all necessary operations, refit the fork legs and the front wheel as described in section "Y".

Set height "A" back to original value.

TIGHTENING TORQUE FIGURES 3 = 25 Nm/ 2.5 Kgm/ 18.44 ft/lb

3 Fork spring features Length = 380 mm Constant K = 3.5 Nm Fork oil Oil level 100 Âą 2 mm

Level 100 Âą 2 mm (without spring, preload tube, and with tube fully home) Oil quantity in each fork leg: 210 cu. cm

Workshop Manual Ed. 09-2011 I.5

FRONT SUSPENSION

CR 65 Cleaning the fork legs dust seals Position the bike on a stand to lift up the front wheel, and push down the dust seals protections on both fork legs.

The dust seals protections remove dirt from the fork legs that builds up when using the vehicle, protecting the fork internal side. Clean the dust seals to prevent part of the built-up dirt on the legs from entering inside the fork and thus damaging the oil seals with consequent sealing loss.

1

Any oil leakage from the fork legs can represent a danger when using the vehicle since the presence of oil on the brake disc or on the pads reduces the braking effect.

In case of contacts between friction parts and oil, thoroughly clean with detergent suitable for brakes.

- Clean and lubricate the dust seals and the internal tube on both fork legs.

- Refit the dust seal protections by perfectly matching them with the outer tube.

- Remove the exceeding oil.

Workshop Manual Ed. 09-2011 I.6

REAR SUSPENSION

CR 65

Section

J

Workshop Manual Ed. 09-2011 J.1

REAR SUSPENSION

CR 65 Rear shock absorber......................................................................................J.3 Rear suspension............................................................................................J.3 Removing the rear shock absorber................................................................J.4 Removing the chain rear casing.....................................................................J.4 Disassembling and servicing the swinging arm..............................................J.5 Servicing the swinging arm pivot....................................................................J.7 Servicing the rear rocker arm and suspension drop drag link........................J.7 Chain roller, chain guide, chain slider.............................................................J.8 Adjusting the shock absorber ........................................................................J.8

Workshop Manual Ed. 09-2011 J.2

REAR SUSPENSION

CR 65 Rear shock absorber TIGHTENING TORQUE FIGURES 1 = 70 Nm/ 7.1 Kgm/ 51.63 ft/lb + Loctite 243 2 = 50 Nm/ 5.1 Kgm/ 36.88 ft/lb + Loctite 243

1 2

LUBRICATION POINTS (GREASE)

Rear suspension The suspension of this motorcycle consists of a shock absorber, a series of linkages and a swinging arm. The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions. The hydraulic damping can be adjusted both in rebound and in compression. Periodically check all components for wear.

Workshop Manual Ed. 09-2011 J.3

REAR SUSPENSION

CR 65 Rear shock absorber removal - Remove the front retaining pin (1) of the drag link (2) of the suspension on the chassis.

2

1

- Remove the shock absorber lower retaining screw (3) and the upper one (4), and then slide the shock absorber (5) out.

3 Upon reassembly insert the upper pin (4) from the right to the left, and the lower one (3) from the left to the right.

5

4

Removing the chain rear casing

1

- Remove the rear chain protection casing (1) by cutting the two ties (2) that fasten it to the swinging arm.

2

Workshop Manual Ed. 09-2011 J.4

REAR SUSPENSION

CR 65 Disassembling and servicing the swinging arm - Set a stand under the engine and see that the rear wheel is lifted from the ground.

- Remove the secondary drive chain (1) and detach the rear brake line (2) from the guide (A) on the swinging arm.

1

2

A

- Remove the wheel axle nut (3) and the wheel axle (B): There is no need to loosen the chain tensioners (4) on the swinging arm; in this way, the chain tension will remain unchanged after reassembly.

4

3 - Slide the wheel (C) out.

- Remove the pin (5) that connects the shock absorber linkage to the swinging arm (A).

A

B

C

5

Workshop Manual Ed. 09-2011 J.5

REAR SUSPENSION

CR 65 - Remove the plug (1) of the shaft nut (2) locking the swinging arm onto the chassis.

1

2

3

A

- 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.

B

4

3

E

- Check the swinging arm pivot (3) parallelism.

- Check for wear of the needle roller bearings (D) and the relevant pins (E); turn the pins inside the roller bearings: if you feel any tightness or hear noise, replace them.

TIGHTENING TORQUE FIGURES 2-3 =70 Nm / 7.1 Kgm / 51.63 ft/lb + Loctite 243

D

Workshop Manual Ed. 09-2011 J.6

REAR SUSPENSION

CR 65 Servicing the swinging arm pivot Check shaft taper using a dial gauge. Place the shaft on two identical reference blocks. Turn the shaft and move the dial gauge horizontally to determine the amount of distortion.

Service limit: 0.30 mm.

Servicing the rear suspension drop and drag link With drop link (1) and drag link (2) still in place (connected to swinging arm and chassis, respectively), rock them both back and forth in all directions to check for radial and axial clearance. Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation. If any radial clearance is detected, remove the part from swinging arm or chassis and check inner spacer (A), bushings (C), (D) and bearings (B) for wear. Grease the inner race of the bearings before refitting them.

5

4 1

2 6

3

TIGHTENING TORQUE FIGURES 3-4-5 =70 Nm / 7.1 Kgm / 51.63 ft/lb + Loctite 243 6 =50 Nm / 5.1 Kgm / 36.88 ft/lb + Loctite 243

D

B 1

B

D

A B

C

B 2

B

C Workshop Manual Ed. 09-2011 J.7

REAR SUSPENSION

CR 65 3

4

Chain roller, chain guide, chain slider Check the wear of the above-mentioned elements and replace them when necessary.

Check the chain guide alignment, and remember that a bent element can cause chain early wear. In this case, chain might unwrap from the sprocket.

1 Chain roller

1

2 Chain guide

2

3 Chain slider 4 Master link Shock absorber adjustment The 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.

B

The shock absorber adjustment affects both the stability and the handling of the motorcycle. We recommend to act carefully after having changed the standard setting. Before performing any change we recommend to measure a reference value "A" with bike on the central stand and rear wheel lifted from the ground.

A C

- 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 25รท30 mm (0.98 รท 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 60รท70 mm (2.36 รท 2.76 in).

B: silencer retaining screw axle C: rear wheel axle height

Workshop Manual Ed. 09-2011 J.8

BRAKES

CR 65

Section

L

Workshop Manual Ed. 09-2011 L.1

BRAKES

CR 65 Braking system.............................................................................................. L.3 Brake disc...................................................................................................... L.4 Checking brake pads for wear / replacing the pads...................................... L.5 Pads removal................................................................................................ L.5 Pads installation............................................................................................ L.5 Bleeding the front braking system................................................................. L.6 Bleeding the rear braking system.................................................................. L.7 Changing the fluid......................................................................................... L.8

Workshop Manual Ed. 09-2011 L.2

BRAKES

CR 65 Braking system

3

The braking system uses two independent circuits. Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir.

1. Front brake lever 2. Front brake master cylinder with fluid reservoir 3. Front brake line 4. Front brake calliper 5. Front brake disc 6. Rear brake fluid reservoir 7. Rear brake line 8. Rear brake calliper 9. Rear brake disc 10. Rear brake master cylinder 11. Rear brake control pedal

1 2

3

5

4

8

7

9

10

6 11

Workshop Manual Ed. 09-2011 L.3

BRAKES

CR 65 Brake disc Checking the brake disc is an important safety procedure; the disc must be spotless, i.e. free from corrosion, oil or other dirt or deep scoring.

Front brake disc diameter: . ...................................................................260 mm Front brake disc thickness (when new): .................................................3.0 mm Wear limit: ..............................................................................................2.5 mm Rear brake disc diameter: .....................................................................mm 140 Rear brake disc thickness (when new): . ..............................................mm 3.10 Wear limit: ..............................................................................................2.5 mm Disc warpage must not exceed 0.15 mm (check disc mounted on the rim with a dial gauge).

To remove the disc from the wheel rim, you need to loosen the four retaining screws. On assembly, clean all mating surfaces thoroughly and tighten the screws to the specified torque.

Workshop Manual Ed. 09-2011 L.4

BRAKES

CR 65 Checking brake pads for wear / replacing the pads

A

Check brake pad wear.

Service limit �A�

- 1 mm (front and rear pads) If service limit is exceeded, always replace the pads in pairs.

Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.

Replace the pads with new ones if they cannot be cleaned satisfactorily.

FRONT

Pads removal

2

- Remove the retaining ring (1) on the front calliper or the split pin (5) on the rear calliper.

- Loosen the pin (2).

- Remove the pads (4).

Do not work the brake lever or pedal while removing the pads.

4

1 Pads installation - Fit the new brake pads (4) having care to position the clip (3) correctly.

- Screw the pin (2) and refit the retaining ring (1) on the front calliper, or the split pin (5) on the rear one.

3

The retaining ring (1) is a safety component, so make sure it is properly fitted.

Acting as described above, after replacing the pads it is not necessary to bleed the system, just act the control lever several time until the pistons get in the normal position.

REAR

5 4

2

Workshop Manual Ed. 09-2011 L.5

BRAKES

CR 65 Bleeding the front braking system A long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding.

Bleeding procedure is as follows: - Take the rubber cover off the bleed valve (1).

- Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel (make sure the hose end stays dipped in the fluid throughout the procedure).

- Remove the reservoir cover (2) and the rubber gaiter and fill the reservoir with DOT 4 fluid.

- Completely pull the lever (3).

- Loosen the bleed valve and drain the fluid (only air at first), then slightly close the valve.

- Release the lever and wait a few seconds. Repeat the process until you see only fluid coming out of the hose.

- Tighten the bleed valve to the indicated torque, restore the fluid level (A) and refit the rubber gaiter (4) and cover (2) of the tank.

1

Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure.

Brake fluid is corrosive. In the event of contact with eyes, rinse with abundant water.

Motorcycle handlebar must be turned to the left during the bleeding procedure. This will keep the master cylinder reservoir higher, making bleeding easier.

If brake lever or brake pedal feel mush after a fall or a repair resulting in loss of braking, bleed the circuit as described above.

Bleed valve tightening torque: 12รท16 Nm/ 1.2รท1.6 Kgm/ 8.7รท11.6 ftlb.

2

3

2 4 3 mm

A

Workshop Manual Ed. 09-2011 L.6

BRAKES

CR 65 Bleeding the rear braking system A long travel and mushy feel of the brake pedal indicate that there is air in the system and the brake needs bleeding.

Bleeding procedure is as follows: - Remove the protection cap and connect a clear hose to the bleed valve (1) of the calliper. Insert the other end of the hose in a container.

- Remove the tank cover (A) (3 mm Allen wrench), the diaphragm and fill with fluid (DOT 4).

- Press the pedal (2) fully down.

- Loosen the bleed valve and drain the fluid (only air at first), then slightly close the valve.

- Release the pedal and wait a few seconds. Repeat the process until you see only fluid coming out of the hose.

- Tighten the bleed valve to the specified torque and check fluid level (B) in the reservoir before refitting the cap (A). If the bleeding procedure was performed correctly, the pedal will no longer have that mushy feel. If not so, repeat the procedure.

1

Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure.

If brake lever or brake pedal feel mush after a fall or a repair resulting in loss of braking, bleed the circuit as described above.

A

Bleed valve tightening torque: 12รท16 Nm/ 1.2รท1.6 Kgm/ 8.7รท11.6 ftlb

2

B

Workshop Manual Ed. 09-2011 L.7

BRAKES

CR 65 Changing the fluid Brake fluid should be checked and changed as per the "Maintenance Chart" (see page B.3) or earlier if contaminated with debris or water. Do not change brake fluid in the rain or with a strong wind.

Use only fluid taken from a sealed container (DOT 4). Never reuse brake fluid.

1

Avoid the ingress of contaminants such as dirt, water, etc. into the reservoir.

Do not keep the reservoir open without its cover longer than necessary; this would increase the risk of contamination.

Handle the fluid with care to avoid damage to painted parts.

1A

Do not mix two brands of fluid. This would reduce boil-over point, leading to loss of braking efficiency or degrading of rubber parts.

Replacement procedure is as follows: - Take the rubber cover off the bleed valve (1) or (1A).

- Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel.

Workshop Manual Ed. 09-2011 L.8

BRAKES

CR 65

3 2

- Remove the reservoir cover (2) or (2A) and the rubber gaiter.

- Loosen the bleed valve on the calliper.

- Pump the brake lever (3) or the brake pedal (3A) until draining all fluid.

- Tighten the bleed valve and fill the reservoir with fresh fluid.

- Loosen the bleed valve, operate lever or pedal, tighten the valve keeping lever or pedal pressed and then release them.

- Repeat the process until the circuit is full and you can see clear fluid coming out of the plastic hose: now tighten the bleed valve.

- Top up with fluid up to level (A) or (B) and refit rubber gaiter and reservoir cover.

After changing the fluid, you will need to bleed air from the circuit.

3A

3 mm

A

2A

B

Workshop Manual Ed. 09-2011 L.9

ELECTRICAL SYSTEM

CR 65

Section

M

Workshop Manual Ed. 09-2011 M.1

ELECTRICAL SYSTEM

CR 65 Wiring diagram............................................................................................. M.3 Electrical components location..................................................................... M.4 Spark plug ................................................................................................... M.5 Handlebar switches...................................................................................... M.6 Left-hand switch........................................................................................... M.6 Ignition system resistance values - stator.................................................... M.6 Ignition coil................................................................................................... M.6 Ignition static parameters measurement with peak voltage adapter............ M.7 Important...................................................................................................... M.8

Workshop Manual Ed. 09-2011 M.2

ELECTRICAL SYSTEM

CR 65 Wiring diagram

black

Stop button Pulsante di arresto

Ignition coil Bobina di accensione

ye-bl

orange

Generator Generatore blue-white red-black green-white

G

U

red-white

pick up

E C

red-green

3

black

black

Cable colour bk : black bl : blue gn : green or : orange re : red ye : yellow wh : white Workshop Manual Ed. 09-2011

M.3

ELECTRICAL SYSTEM

CR 65 Electrical component location The ignition system includes the following elements: - Generator (1), on the inner side of L.H. crankcase half cover;

1

- Electronic ignition coil (2) under the tank on the chassis right side;

2

- Electronic control unit (3) on steering tube rake, behind the Number holder;

3

Workshop Manual Ed. 09-2011 M.4

ELECTRICAL SYSTEM

CR 65 Spark plug The spark plug (4) is a "NGK" BR8 ECM spark plug. Check electrode gap "A" (0.6 mm). A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed. Clean off any dirt around spark plug base before removing the spark plug. It is good practice to closely inspect the spark plug after removal, as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating, carburetion, ignition and the general condition of the engine. Before refitting the spark plug, accurately clean the insulator with a wire brush. Smear some graphite grease on spark plug thread, do it fully home finger tight then tighten it to 10รท12 Nm torque. Loosen the spark plug then tighten it again to 10รท12 Nm. Spark plugs which have cracked insulators or corroded electrodes should be replaced.

4

Workshop Manual Ed. 09-2011 M.5

ELECTRICAL SYSTEM

CR 65 Handlebar switches Measure continuity on the different switches using a meter. Replace any part found to be faulty.

Left-hand switch 1 Engine stop switch (1) COLOUR POSITION

1

Bl-Wh

Bl

ON OFF

Ignition system resistance values - stator – Disconnect the stator plug and use a digital multimeter to measure the stator winding resistances at 20 °C. Impulse transmitter: across white/red cable and white/blue cable

reading on multimeter: 310 Ω +/- 60 Ω CDI unit voltage supply: across green/red cable and black cable

reading on multimeter: 55 Ω +/- 10 Ω Condenser charge coil: across black/red cable and green/white cable

reading on multimeter: 900 Ω +/- 180 Ω WARNING: it is not necessary to remove the stator to take the measurement.

Ignition coil – Loosen the spark plug cap and disconnect the cable that controls the primary side.

– Measure the resistance of the ignition coil primary side across the plug controlling the primary side and the ignition coil ground.

reading on multimeter: lower than 10 Ω a 20 °C

– Measure the resistance of the ignition coil secondary side across the high voltage cable and the ignition coil ground.

reading on multimeter: 7900 Ω +/- 1600 Ω at 20 ºC

WARNING: it is not necessary to remove the ignition coil to take the measurement.

Workshop Manual Ed. 09-2011 M.6

ELECTRICAL SYSTEM

CR 65 Ignition static parameter measurement with peak voltage adapter Measurement conditions: – cold engine – remove the number holder – loosen the spark plug, connect it and keep it to ground – all connector couplings and connections to ground must be free of corrosion signs – for each measurement strongly press the kick start pedal at least 5 times fully down.

2

1

Check if the impulse transmitter gives an output signal – white/red and white/ blue cables: – the red prod of the peak voltage adapter on the white/red cable, the black prod on the white/blue cable, then separate the connector (1); in this way the CDI unit (2) is disconnected.

reading on multimeter: 10 volt +/- 1 volt – Same measurement, but with CDI unit connected

reading on multimeter: 6 volt +/- 1 volt Check CDI unit voltage supply on output voltage – green/red and black cables: – the red prod of the peak voltage adapter on the green/red cable, the black prod on the black cable, then separate the connector (1).

reading on multimeter: 40 volt +/- 5 volt – Same measurement, but with CDI unit connected

reading on multimeter: 35 volt +/- 5 volt Check the condenser charge coil on output voltage – – black/red and green/white cables: – the red prod of the peak voltage adapter on the black/red cable, the black prod on the green/white cable, then separate the connector (1)

reading on multimeter: 270 volt +/- 20 volt – Same measurement, but with CDI unit connected

reading on multimeter: 230 volt +/- 20 volt Check the primary voltage output that controls the ignition coil on the output voltage (orange cable): – the peak voltage adapter red prod to the ground, and the black one to the orange cable, CDI unit and ignition coil connected

reading on multimeter: 230 volt +/- 20 volt

WARNING: if upon one check it is not possible to measure a voltage value, we recommend to check the continuity across the cables before replacing the parts.

Workshop Manual Ed. 09-2011 M.7

ELECTRICAL SYSTEM

CR 65 IMPORTANT Before washing the motorcycle, it is necessary to duly protect the following parts from water: a) Rear opening of the muffler; b) Clutch and front brake levers, handgrips, handlebar switches; c) Air filter intake; d) Steering head, wheel bearings; e) Rear suspension drag drop link.

It is necessary to PREVENT WATER OR HIGH PRESSURE AIR JETS from reaching the ELECTRIC PARTS.

Workshop Manual Ed. 09-2011 M.8

ENGINE COOLING

CR 65

Section

N

Workshop Manual Ed. 09-2011 N.1

ENGINE COOLING

CR 65 Coolant level check.......................................................................................N.3 Cooling circuit ...............................................................................................N.4 Engine cooling system overhaul . .................................................................N.5

Workshop Manual Ed. 09-2011 N.2

ENGINE COOLING

CR 65 Coolant level check Coolant takes the heat from the piston-cylinder-and-head assembly and transfers it to the radiator, where it is released to the atmosphere. Checking coolant level at regular periods is critical to ensuring proper operation of the cooling system.

1

Without cooling medium (water), no heat exchange occurs between cylinder head and radiator. The cylinder and piston assembly will overheat and seize and in the worst scenario, crankshaft damage may result.

If the event of engine overheating, check that the radiator is full.

Level in the radiator must be checked from cold (see Section D).

In the event you need to check level when the engine is hot, be sure to discharge pressure gradually.

Loosen the plug (1) of the radiator to check the fluid level.

Failure to follow the above instructions will create a risk of scalding for operator and any persons standing nearby.

A. Coolant level B. Breather hose

Workshop Manual Ed. 09-2011 N.3

ENGINE COOLING

CR 65 Cooling circuit

1

6

4 9 7

2

3 8

10

5 The forced circulation cooling system uses a centrifugal pump (located to the right of the cylinder head) and two downdraft radiators.

1 2 3 4 5 6 7 8 9 10

Radiator cap Right-hand radiator Left-hand radiator Radiator to head pipe Water pump Breather hose Radiator connecting pipes Water pump / radiator lower pipe Head / water pump pipe Coolant bleeding screw

Workshop Manual Ed. 09-2011 N.4

ENGINE COOLING

CR 65 Servicing the engine cooling system

1 2 6

3

If the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected. If damage exceeds this limit, the radiator must be replaced. Periodically check the connecting hoses (see Section B, “Scheduled Maintenance Chart�); this will avoid coolant leakage and consequent engine seizure. If hoses show cracks, swelling or hardening due to sheaths desiccation, their replacement shall be advisable. Check the correct tightening of the clamps.

7 4

9 5 10

8

Workshop Manual Ed. 09-2011 N.5

HYDRAULICALLY CONTROLLED CLUTCH

CR 65

Section

P

Workshop Manual Ed. 09-2011 P.1

HYDRAULICALLY CONTROLLED CLUTCH

CR 65 Hydraulic clutch system..................................................................................P.3 Draining clutch fluid........................................................................................P.4 Servicing the clutch master cylinder...............................................................P.4 Filling/draining the clutch hydraulic system....................................................P.5

Workshop Manual Ed. 09-2011 P.2

HYDRAULICALLY CONTROLLED CLUTCH

CR 65 3 1 7

5 2 6

9 10 4 8 Hydraulic clutch system The hydraulic circuit is composed of a master cylinder with its reservoir located on the left side of the handlebar, and a piston installed on the right crankcase half. The clutch is disengaged by the piston (5) that operates the pressure plate (4). Drive is transmitted from the crankshaft to the gearbox input shaft via the gear on the clutch housing (8). The clutch housing accommodates friction plates (9) and steel plates (10) that operate the clutch hub (6) secured to the gearbox input shaft.

1- Clutch master cylinder 2- Clutch lever 3- Master cylinder to piston hose 4- Pressure plate 5- Actuator piston 6- Clutch hub 7- Bleed fitting 8- Clutch housing with clutch ring gear 9- Steel plate 10- Friction plate The fluid used in the hydraulic circuit will damage painted parts if spilt on them. Handle it with care when servicing the system.

Workshop Manual Ed. 09-2011 P.3

HYDRAULICALLY CONTROLLED CLUTCH

CR 65 Draining clutch fluid Connect a plastic hose to the bleed valve and loosen the valve turning it back by 1 or 2 turns. Remove reservoir cap and bellow diaphragm and operate the control lever until draining all fluid.

Clutch master cylinder servicing Drain the circuit, detach the master cylinder from the left side of the handlebar and take it apart. Replace all seals, reassemble the master cylinder and refit it to the handlebar. Reconnect the hose and fill fresh fluid into the reservoir. Bleed the system as described at page P.4.

Workshop Manual Ed. 09-2011 P.4

HYDRAULICALLY CONTROLLED CLUTCH

CR 65 2

1 4

3 mm

Filling/draining the clutch hydraulic system Proceed as follows: - Remove screws (1), cover (2) and rubber diaphragm (4); - Remove the rubber cap (3) and loosen the bleed valve (5); - Connect the bleed valve to a pipe, and use a syringe (6) to fill in the fluid (of the type specified in the LUBRICANT TABLE at page A.9) until topping-up the master cylinder reservoir.

NEVER use brake fluid.

A

- Check that fluid level is never lower than 3 mm below the upper edge (A) of master cylinder body. Refit any parts you have removed.

- Make sure the clutch lever reacts properly when activated: otherwise, bleed again until removing all the air in the system.

3

3

5

5

6

Workshop Manual Ed. 09-2011 P.5

FUEL SUPPLY

CR 65

Section

S

Workshop Manual Ed. 09-2011 S.1

FUEL SUPPLY

CR 65 Carburettor setting......................................................................................... S.3 Original setting..............................................................................................S.3 Main information about carburettor wear.......................................................S.3 Idle rpm – A, Idle adjustment......................................................................... S.4 Valve opening – B.......................................................................................... S.4 Partial load – C.............................................................................................. S.4 Full load – D.................................................................................................. S.4 Carburettor drawing....................................................................................... S.5 Removing and refitting the carburettor.......................................................... S.6 Disassembling the carburettor....................................................................... S.8 Checking the cold start device...................................................................... S.9 Checking taper needle and throttle valve.................................................... S.10 Checking the floater needle valve............................................................... S.10 Checking carburettor jets and gaskets........................................................ S.10 Reassembling the carburettor..................................................................... S.10 Emptying the carburettor bowl..................................................................... S.11 Checking the floater level ........................................................................... S.11

Workshop Manual Ed. 09-2011 S.2

FUEL SUPPLY

CR 65 Carburettor setting Original setting The carburettor original settings are: 500 m altitude above sea level, temperature of nearly 20 °C, main use off-road and possibility of using premium grade fuel in Central Europe (RON 95, without lead), mixed with 2T oil. Oil-fuel mixture ratio at 3% during running-in phase, at 2% after running-in.

GENERAL RULE: high altitudes or temperatures ð lean mixture low altitudes or temperatures ð rich mixture – USE ONLY PREMIUM GRADE FUEL (NO. 95), MIXED WITH 2T HIGH QUALITY ENGINE OIL. OTHER TYPES OF FUEL CAN CAUSE DAMAGES TO THE ENGINE. – FEW OR LOW QUALITY OIL CAUSES EARLY WEAR OF THE ENGINE AND, IN EXTREME CASES, IRREPARABLE DAMAGES. TOO MUCH OIL CAUSES EXCESSIVE SMOKE AND SOILS THE SPARK PLUG AND THE EXHAUST VALVE. – TO GET A LEAN MIXTURE, CAREFULLY REDUCE THE JETS STEP BY STEP BY ONE NUMBER RESPECTIVELY TO AVOID PISTON OVERHEATING AND SEIZURE. WARNING: If, despite the setting change, the engine does not work properly, check for mechanical faults or problems in the ignition system.

Main information about carburettor wear Because of the engine vibrations the throttle valve, the floater taper needle, and the main nozzle are subject to high wear. Wear causes carburettor malfunctions (for example too rich mixture). Check and/or replace such parts every 100 operating hours.

Carburettor settings Summer

Winter

Maximum jet

240

210

Minimum jet

40

40

3rd notch

2nd notch

3 (from fully closed)

2 (from fully closed)

Taper needle position Air screw turns

Workshop Manual Ed. 09-2011 S.3

FUEL SUPPLY

CR 65 Idle rpm – A, Idle adjustment Operation with closed throttle valve. This rpm is controlled by the position of the air adjuster screw (1) and the throttle valve stop screw (2).

Any adjustment shall be carried out with warm engine only.

To this end slightly increase the engine idle rpm through the throttle valve stop screw. Turn it clockwise to increase the idle rpm, or counterclockwise to decrease it. Work the air adjuster screw to get a regular and stable engine operation (air adjuster screw base adjustment = opened by 3 turns). Afterwards adjust the idle rpm again by means of the throttle valve stop screw.

1

Valve opening – B Operation with throttle valve during opening phase. Rpm are controlled by the idle jet and the valve shape. If despite a correct idle and partial pre-load adjustment upon valve opening the engine gallops, releases a lot of smoke and reaches its maximum power suddenly at high rpm, that means the carburetion is too rich, i.e. the fuel level is too high or the main nozzle does not feature a proper sealing.

Partial load – C Operation with throttle valve partially opened. Rpm are controlled by the taper needle only (shape and position). The operation at partial load at low rpm is determined by the idle adjustment and the maximum jet peaks. If the engine turns with one 4-stroke cycle or with reduced power upon acceleration with throttle valve partially open, it is necessary to lower the needle by one notch.

If the engine knocks, especially upon acceleration and near high rpm, it is necessary to lift up the needle.

If what described above occurs at the lowest rpm of partial load, have a leaner mixture if the engine gets flooded, or a richer one if the engine knocks.

Full load – D Operation with valve completely open. Rpm are controlled by the maximum jet and the taper needle. If, after a short distance at maximum speed, the sealant of a new spark plug appears very clear or white, it will be necessary to use a bigger maximum jet; if it appears dark or black, use a smaller one.

Workshop Manual Ed. 09-2011 S.4

2

D

Tapermassimo needle Getto Spillo conico maximum jet

C

Spillo Taper needle conico

B A

Minimum jet Getto minimo valve Valvola Minimum jet Getto minimo

FUEL SUPPLY

CR 65 Carburettor drawing

1 2 3 4 5 6 7

Air adjusting screw Throttle valve spring Air adjuster spring Throttle valve Needle valve Taper needle Maximum jet seat

8 Maximum jet 9 Minimum jet 11 Cold kick start lever 13 Floater bowl 14 Floater + pin 15 PVC hose 16 Idle adjustment screw Workshop Manual Ed. 09-2011 S.5

FUEL SUPPLY

CR 65 Removing and refitting the carburettor

1

WARNING: before acting on the carburettor, thoroughly clean the motorcycle.

– Close the fuel cock (1) and remove the pipe (2) from the carburettor.

2

– Remove the clamp (3) and release the carburettor breather pipes from the transmission oil breather pipe.

3

– Loosen the two screws (4).

4

5

– Remove the cover (5) of the carburettor together with the throttle valve.

Workshop Manual Ed. 09-2011 S.6

FUEL SUPPLY

CR 65 6

– Loosen the clamp (6) on the filter box connection unions.

– Remove saddle and side panels as described in Section "E".

8

– Disconnect the silencer from the rear chassis supporting plate.

– Remove the two lower screws (7) and loosen the two upper screws (8) that connect the rear chassis to the front chassis.

7

– Turn the rear chassis (9) to completely release the carburettor from the union (10) that connects the air filter.

10

9

– Loosen the tie (11) and remove the carburettor from the intake fitting.

11

Workshop Manual Ed. 09-2011 S.7

FUEL SUPPLY

CR 65 Disassembling the carburettor WARNING: Before starting disassembling the carburettor, prepare and clean the working area. Such area should be sufficiently big to arrange in an orderly way all carburettor single components.

1 2

– Disconnect all carburettor breather pipes.

– Loosen the four screws (1) and remove the float chamber (2) with the relevant gasket.

1 – Remove the floater (3) axle.

– Remove the floater with the needle from the needle valve.

3

– Remove the maximum jet (4).

– Remove the screw (5) of the floater needle valve body retaining plate (7).

- Remove the minimum jet (6).

6 4 5 7

Workshop Manual Ed. 09-2011 S.8

FUEL SUPPLY

CR 65 – Remove the idle adjusting screw (8) together with the spring.

8

– Screw the air adjuster screw (1) fully home counting and recording the turns.

– Remove the air adjuster screw, the spring, the washer and the O-ring.

1

Checking the cold start device – To remove the starting piston (2) it is necessary to straighten the bent washer to be able to loosen the retaining nut (3).

– The cold start device must be easy to activate.

2

3

– The piston (4) must not feature evident scratching or deposits.

4

Workshop Manual Ed. 09-2011 S.9

FUEL SUPPLY

CR 65 Checking the taper needle and throttle valve – Check that the taper needle (3) is not worn out or deformed.

3

Because of the engine vibrations the throttle valve, the floater taper needle, and the main nozzle are subject to high wear. Wear causes carburettor malfunctions (for example too rich mixture). Check and/or replace such parts every 100 operating hours.

Checking the floater needle valve – Check for no dents on the needle valve sealing surface.

– There must be no dirt between the valve seat and the floater needle.

Checking the carburettor jets and gaskets – Thoroughly clean all carburettor components and blow them with compressed air.

– Replace all gaskets and O-rings.

Reassembling the carburettor For reassembly follow the removal procedure in the reverse order.

Consider what follows: – Check operation and stop of cold start device.

– Loosen the air adjuster screw by the number of turns previously recorded upon disassembly. For carburettor original setting see section Technical data.

Workshop Manual Ed. 09-2011 S.10

FUEL SUPPLY

CR 65 Emptying the carburettor bowl – Close the fuel cock and place a cloth under the carburettor able to absorb fuel flowing out.

– Open the closure screw 1, have the residual fuel flowing into the bowl, and clean the closure screw with compressed air.

Afterwards refit the closure screw with its seal and tighten it to 4 Nm; then open the fuel cock and check for no leakages in the bowl.

1

21,1mm+0,00mm -0,50mm

Checking the floater level – Place the carburettor with the floater high horizontally.

– The spring in the floater needle valve must not be compressed.

– In this position the distance between the floater edge and the carburettor mm edge must be of 21.1 mm +0.00 - 0.50 mm

1

Workshop Manual Ed. 09-2011 S.11

SPECIAL TOOLS

CR 65

Section

W

Workshop Manual Ed. 09-2011 W.1

SPECIAL TOOLS

CR 65 SPECIAL TOOLS

HUSQVARNA CODE

DESCRIPTION

1 8000 H7677

Crankshaft removing tool

2 Commercial

Bearing puller

3 Commercial

Insert for bearing puller 12 - 16 mm

4 8000 H7678

Primary gear retainer

5 Commercial

Flywheel and clutch retainer

6 8000 H7679

Spark advance adjusting gauge

7 8000 46613

Flywheel puller

8 Commercial

Puller

9 Commercial

Pliers for cooling system clamps

1

2

4

3

6 ignition

8

cylinderheight

9

5

Workshop Manual Ed. 09-2011 W.2

7

TIGHTENING TORQUE FIGURES

CR 65

Section

X

Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent.

Workshop Manual Ed. 09-2011 X.1

TIGHTENING TORQUE FIGURES

CR 65 CHASSIS MEASURE

Qty

NOMINAL TORQUE (Nm)

NOTES

Chain roller to chassis retaining screw

M8

1

25

LOCTITE 243

Front low. and upp. engine retaining screw

M8

2

35

LOCTITE 243

Engine lock nut

M8

2

35

LOCTITE 243

Rear chassis to chassis connecting screw

M8

4

25

Stand support upper retaining screw

M6

1

10

Coil to chassis retaining screw

M6

2

10

Saddle engagement plate retaining screw

M8

2

8

Saddle to tank retaining screw

M6

1

6

DESCRIPTION

LOCTITE 243

HANDLEBAR AND CONTROLS MEASURE

Qty

NOMINAL TORQUE (Nm)

Check nut for lug adjustment

M6

1

10

Lever joint retaining screw

M6

1

10

LOCTITE 243

Brake lever to chassis retaining screw

M10

1

35

LOCTITE 243

Cam retaining screw

M6

1

10

Front brake hose clamp to fork retaining screw

M5

2

6

Front brake hose clamp to fork retaining nut

M5

2

6

Gear shift pedal retaining screw

M6

1

10

Clutch protection retaining screw

M6

1

10

MEASURE

Qty

NOMINAL TORQUE (Nm)

U-bolt to steering head retaining screw

M10

2

35

U-bolt closing screw

M8

4

28

Fork plate retaining TORX screw

M8

7

25

Fork guard to fork bottom retaining screw

M6

6

6

DESCRIPTION

NOTES

FRONT SUSPENSION DESCRIPTION

Steering upper nut

10

1 Nm = 0.73756 ft/lb

Workshop Manual Ed. 09-2011 X.2

NOTES

TIGHTENING TORQUE FIGURES

CR 65 REAR SUSPENSION MEASURE

Qty

NOMINAL TORQUE (Nm)

Chain slider on fork retaining screw

M5

1

6

Rear chain guide retainers

M6

1

10

Shock absorber to chassis retaining screw

M10

1

70

LOCTITE 243

Shock absorber to rocker arm retaining screw

M10

1

50

LOCTITE 243

Shock absorber low. and upp. lock nut

M10

2

50

LOCTITE 243

Drag link to chassis connecting screw

M12

1

70

Drag link to rocker arm connecting screw

M12

1

70

Rocker arm to swinging arm connecting screw

M12

1

70

Rocker arm screws retaining nut

M12

3

70

LOCTITE 243

Swinging arm pivot retaining nut

M12

1

70

LOCTITE 243

2

4

DESCRIPTION

Rear brake hose ring retaining self-threading screw

NOTES

MUDGUARD FAIRINGS MEASURE

Qty

NOMINAL TORQUE (Nm)

Front mudguard retaining screw with collar

M6

4

6

Number holder retaining screw with collar

M6

1

6

4

1.5

2

6

2

1.5

DESCRIPTION

Front mudguard part connection screw Rear mudg. front retaining screw with collar

M5

Number holder to rear mudg. retaining screw Side panel rear retaining screw with collar

M5

2

6

Side panel to rear chassis and tank retaining screw with collar

M5

6

6

Side panel front retaining screw with collar

M6

2

6

Filter box cover retaining screw with collar

M5

1

6

Clip nut

M5

2

6

Wheelhouse to rear chassis front retaining screw

M6

2

8

Wheelhouse to rear chassis retaining screw

2

1.5

Wheelhouse to rear mudguard connection screw

2

1.5

2

6

4

1.5

Wheelhouse to shock absorber protection retaining screw

M5

Filter box to rear chassis support retaining screw

NOTES

1 Nm = 0.73756 ft/lb

Workshop Manual Ed. 09-2011 X.3

TIGHTENING TORQUE FIGURES

CR 65 SUPPLY SYSTEM DESCRIPTION Tank front retaining screw

MEASURE

Qty

NOMINAL TORQUE (Nm)

M6

1

6

2

1.5

Cock retaining self-threading screw

NOTES

WHEELS AND BRAKES MEASURE

Qty

NOMINAL TORQUE (Nm)

NOTES

Front brake disc retaining screw

M6

3

10

LOCTITE 243

Front wheel axle retaining screw

M10

1

45

Front wheel axle to fork retaining screw

M6

2

10

Rear brake disc retaining screw

M6

4

10

Sprocket retaining nut

M8

5

35

Rear wheel axle

M12

1

85

Rear wheel retaining nut

M12

1

85

Chain tensioner adjusting screw

M6

2

5

Chain tensioner and adjusting nut

M6

2

5

Front brake calliper retaining screw

M8

2

25

LOCTITE 243

Rear brake calliper retaining screw

M8

2

25

LOCTITE 243

Rear brake master cylinder retaining screw

M6

2

10

LOCTITE 243

Rear brake master cylinder retaining nut

M6

2

10

LOCTITE 243

MEASURE

Qty

NOMINAL TORQUE (Nm)

NOTES

Vibration damper to chassis retaining screw

M6

2

10

Vibration damper to chassis retaining nut

M6

2

10

Vibration damper to silencer retaining screw

M6

2

10

Silencer to bracket retaining nut

M6

1

10

Silencer to bracket retaining screw

M6

1

10

Rear chassis to bracket retaining screw

M5

2

6

Silencer end cap retaining screw

M5

2

9

DESCRIPTION

LOCTITE 243

EXHAUST DESCRIPTION

1 Nm = 0.73756 ft/lb

Workshop Manual Ed. 09-2011 X.4

TIGHTENING TORQUE FIGURES

CR 65 COOLING SYSTEM MEASURE

Qty

NOMINAL TORQUE (Nm)

Radiator retaining screw

M6

2

10

Radiator retaining flanged lock nut

M6

2

10

DESCRIPTION

NOTES

1 Nm = 0.73756 ft/lb

NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows

M5x0.8 5.6-6.2 Nm 0.57-0.63 Kgm

M6x1 7.6-8.4 Nm 0.80-0.85 Kgm

M8x1.25 24-26 Nm 2.4-2.6 Kgm

4.1-4.5 ft/lb 5.8-6.1 ft/lb 17.3-18.8 ft/lb

ENGINE (+/- 5%) Primary drive sprocket hexagon nut.............M14x1.25 (+Loxeal 100 HSP)

70 Nm

7.14 Kgm

51.6 ft/lb

Clutch hub retaining screw...........................M10 (+Loxeal 86-54)

50 Nm

5.10 Kgm

36.9 ft/lb

6.12 Kgm

44.3 ft/lb

Cylinder head screws ..................................M7

18 Nm

1.84 Kgm

13.3 ft/lb

Cylinder base flanged nuts...........................M8

18 Nm

1.84 Kgm

13.3 ft/lb

Clutch screws...............................................M6

14 Nm

1.43 Kgm

10.3 ft/lb

Oil bleeding screw........................................M10

12 Nm

1.22 Kgm

8.9 ft/lb

Clutch cover screws.....................................M6

10 Nm

1.02 Kgm

7.4 ft/lb

Clutch hub screws........................................M10

48÷50 Nm

4.89÷5.10 Kgm

35.4÷36.88 ft/lb

Kick start pedal stopping plate.....................M6 (+Loxeal 24/18)

12 Nm

1.22 Kgm

8.9 ft/lb

Stator screw.................................................M5 (+Loxeal 24/18)

8 Nm

0.82 Kgm

5.9 ft/lb

Gear stopping cam retainer..........................M6 (+Loxeal 24/18)

10 Nm

1.02 Kgm

7.4 ft/lb

Spark plug....................................................M14x1.25

25 Nm

2.55 Kgm

18.4 ft/lb

10÷12 Nm

1.02÷1.22 Kgm

7.4÷8.9 ft/lb

Other engine screws....................................M5

6 Nm

0.61 Kgm

4.4 ft/lb

Other engine screws....................................M6

10 Nm

1.02 Kgm

7.4 ft/lb

Flywheel flanged nut M10x1.25/M12x1 .......60 Nm

Engine casing screws...................................M6 (to be greased)

Workshop Manual Ed. 09-2011 X.5

TIGHTENING TORQUE FIGURES

CR 65 INSTALLATION TOLERANCES AND CLEARANCES 0.050 mm Crankshaft ...................................................................max. drive shaft axes misalignment Handwheel external measure . ....................................

57 mm +/- 0.05 mm Connecting rod big end bearing ..................................max. radial clearance 0.030 mm 0.03 mm Max. piston pin ............................................................radial clearance Piston ..........................................................................min. installation clearance 0.065 mm Piston ring ...................................................................max. gap 0.35 mm Clutch springs . ............................................................length when new 27 mm Clutch plates . ..............................................................wear limit 1.8 mm 0.10 - 0.20 mm Gearbox shafts.............................................................axial clearance

NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%) Steel screws on plastic, with metal spacers

M4

2 Nm

0.2 Kgm

1.45 ft/lb

Steel screws on brass, copper, aluminium

M4

2 Nm

0.2 Kgm

1.45 ft/lb

Steel screws on iron, steel

M4

3 Nm

0.3 Kgm

2.2 ft/lb

Steel screws on plastic, with metal spacers

M5

4 Nm

0.4 Kgm

3 ft/lb

Steel screws on brass, copper, aluminium

M5

4 Nm

0.4 Kgm

3 ft/lb

Steel screws on iron, steel

M5

6 Nm

0.6 Kgm

4.4 ft/lb

Steel screws on plastic, with metal spacers

M6

6.5 Nm

0.65 Kgm

4.8 ft/lb

Steel screws on brass, copper, aluminium

M6

6.5 Nm

0.65 Kgm

4.8 ft/lb

Steel screws on iron, steel

M6

10.5 Nm

1 Kgm

7.7 ft/lb

Steel screws on brass, copper, aluminium

M8

16 Nm

1.6 Kgm

11.8 ft/lb

Steel screws on iron, steel

M8

26 Nm

2.6 Kgm

19.1 ft/lb

Steel screws on iron, steel

M10

52 Nm

5.2 Kgm

38.3 ft/lb

Steel screws on iron, steel

M12

100 Nm

10 Kgm

73.8 ft/lb

Steel screws on iron, steel

M14

145 Nm

14.5 Kgm

107 ft/lb

Workshop Manual Ed. 09-2011 X.6

CHASSIS AND WHEELS

CR 65

Section

Y

Workshop Manual Ed. 09-2011 Y.1

CHASSIS AND WHEELS

CR 65 Chassis.......................................................................................................... Y.3 Lubrication points (lubricant)......................................................................... Y.3 Front wheel.................................................................................................... Y.4 Front wheel removal...................................................................................... Y.5 Front wheel installation.................................................................................. Y.6 Rear wheel.................................................................................................... Y.7 Rear wheel removal...................................................................................... Y.8 Wheel servicing............................................................................................. Y.9 Wheel axle warpage...................................................................................... Y.9 Axle runout over 100 mm.............................................................................. Y.9 Wheel spokes.............................................................................................. Y.10 Wheel rim warpage..................................................................................... Y.10 Rear chain sprocket, secondary drive sprocket and chain.......................... Y.11 Check for sprocket wear.............................................................................. Y.12

Workshop Manual Ed. 09-2011 Y.2

CHASSIS AND WHEELS

CR 65 Chassis The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear chassis is made from light alloy.

A badly damaged chassis must be replaced.

1

Lubrication points (lubricant) 1 Steering bearings (grease)

1

Workshop Manual Ed. 09-2011 Y.3

CHASSIS AND WHEELS

CR 65 Front wheel

Light alloy wheel hub and rim with high-strength steel spokes.

Make, type and size of light alloy wheel rims: 1.6x14�

Make, type and size of tyre...................................."Pirelli" Scorpion ...............................................................................MX 60/100 14" 29M NHS

Cold tyre pressure .................................................0.8 Bar

Workshop Manual Ed. 09-2011 Y.4

CHASSIS AND WHEELS

CR 65 Removing the front wheel Set a stand under the engine and see that the front wheel is lifted from the ground.

Loosen the screw (1) placed on the left side;

1

Loosen the two screws (2) that fasten the pin head to the fork bottom on the right side;

3

Slide the pin (3) out from the right side and remove the wheel having care to recover the two spacers (one for each side).

2

Do not operate the front brake lever when the wheel has been removed; this causes the calliper pistons to move outwards.

After removal, lay down the wheel with brake disc on top.

Workshop Manual Ed. 09-2011 Y.5

CHASSIS AND WHEELS

CR 65 Reassembling the front wheel Fit the wheel between the fork legs so as to set the brake disc into the calliper.

Working on right side, push the previously-greased wheel axle (3) all the way down, tapping it on left fork leg; during this operation, the wheel should be turned.

Tighten the two screws (2) that retain the pin head to the fork.

3

2

Tighten the screw (1) on the fork L.H.

1

Remove the stand located under the vehicle Act repeatedly on the front brake lever until bringing the pads against the disc.

Loosen the screws (2) of the fork bottom.

With front wheel braked, act several times on the fork to complete the leg alignment.

Tighten the screws (2) to the specified torque.

Tightening torque figures 1: 45 Nm/ 4.59 Kgm/ 33.19 ft/lb 2: 10 Nm/ 1.02 Kgm/ 7.37 ft/lb

Workshop Manual Ed. 09-2011 Y.6

CHASSIS AND WHEELS

CR 65 Rear wheel

Light alloy wheel hub and rim with high-strength steel spokes.

Make, type and size of light alloy wheel rim: 1.6x12�;

Make, type and size of tyre.............................. "Pirelli" Scorpion;

MX 12" 50M NHS Cold tyre pressure ........................................... 0.8 Bar

Workshop Manual Ed. 09-2011 Y.7

CHASSIS AND WHEELS

CR 65 Removing the rear wheel Set a stand under the engine and see that the rear wheel is lifted from the ground.

Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2); in this way, the chain tension will remain unchanged after reassembly.

2

1

Extract the complete rear wheel, keeping the spacers located at the hub sides.

Do not operate the rear brake pedal when the wheel has been removed; this causes the calliper pistons to move outwards.

3

After removal, lay down the wheel with brake disc on top.

For reassembly follow the removal procedure in the reverse order by inserting the brake disc in the calliper.

2

After reassembly, depress the brake pedal until the pads are against the brake disc.

Tightening torque figures

3

1: 85 Nm/ 8.7 Kgm/ 62.73 ft/lb

Workshop Manual Ed. 09-2011 Y.8

CHASSIS AND WHEELS

CR 65 Wheel servicing Check the wheel hub bearings for wear. If you find too much (radial or axial) clearance, replace the bearings as follows: - place the hub on a flat surface with an appropriate hole (for when you knock out the bearing); - use a hammer and a punch to knock out the bearing; apply pressure only on the inner race of the bearing (see figure); - tap at different positions so as to keep the bearing square in its seat; - remove the spacer and use the same procedure for the other bearing.

Discard the bearings after removal. Never reuse them.

Before installing the new bearings, check to ensure the seat is clean and shows no grooves or scratches. Lubricate the seat before installing the bearing. Drive the bearing into place using the special installer that only applies pressure to the outer race. Fit the spacer and the other bearing. Check for perfect alignment as you slide the axle into place.

Wheels should be balanced after each service.

Wheel axle warpage If warped beyond the maximum limit allowed, the axle must be straightened or replaced. Replace the axle if it cannot be straightened so as to meet the maximum limit allowed.

Axle runout over 100 mm

Wheel axle

Standard

Max. limit

Wheel axle

less than 0.1 mm

0.2 mm (0.0078 in.)

Workshop Manual Ed. 09-2011 Y.9

CHASSIS AND WHEELS

CR 65 Wheel spokes Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Retighten if needed. Improper tightening will affect motorcycle stability; for a quick check, simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear, crisp sound indicates proper tightening, a dull sound means that the spokes need to be tightened.

Wheel rim warpage The table below reports the allowed limits for wheel rim warpage. Exceeding runout or out-of-round are generally due to worn bearings. When this is the case, replace the bearings. If this does not solve the problem, change the wheel rim or the wheel.

Standard

Side runout less than 0.5 mm

Max. limit

Out-of-round less than 0.8 mm

Workshop Manual Ed. 09-2011 Y.10

2 mm (0.078 in.)

CHASSIS AND WHEELS

CR 65 Rear chain sprocket, secondary drive sprocket and chain The figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket.

1 Normal wear 2 Exceeding wear

If the sprocket is exceedingly worn, replace it after loosening the five screws that retain it to the hub.

Chain and sprockets must always be replaced as a set.

Tightening torque figures 3: 15 Nm, 1.5 Kgm, 11.6 ft/lb + LOCTITE 243

Workshop Manual Ed. 09-2011 Y.11

CHASSIS AND WHEELS

CR 65 Checking sprocket wear Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

Wheel misalignment causes abnormal wear, making the motorcycle unsafe to ride.

Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension. If you expect to ride on muddy or wet terrain, slacken the chain a bit. Riding on muddy terrain significantly increases chain and sprocket wear.

Workshop Manual Ed. 09-2011 Y.12