Repair Manual Husqvarna CR 65 2012

CR 65 2012
Workshop Manual
Ed. 09-2011
HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities

for any errors or omissions in this manual and reserves the right to make
changes to reflect ongoing product development. Illustrations in the manual may differ from actual components. No reproduction in full or in part
without written authorisation.
1st Edition (09-2011)
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FOREWORD, TABLE OF CONTENTS
CR 65 2012
Workshop Manual
CR 65 / 2012
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com
1st Edition (09-2011)
Printed in Italy
MODELS COVERED (from serial number onwards)
CR 65 : ZKHCR6530CV000001
H02017
1. Chassis serial number
Workshop Manual Ed. 09-2011

a.1
CR 65 2012
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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".

a.2
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CR 65 2012
Table of Contents
Title
Section
Foreword, Table of Contents................................................................................ a
Important Notices................................................................................................. b
General Information..............................................................................................A
Maintenance.........................................................................................................B
Troubleshooting................................................................................................... C
Settings and Adjustments.................................................................................... D
General Procedures.............................................................................................E
Engine Disassembly.............................................................................................F
Engine Overhaul.................................................................................................. 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.

a.3
IMPORTANT NOTICES
CR 65 2012
Section

b.1
IMPORTANT NOTICES
CR 65 2012
1) CR models are RACING motorcycles and are guaranteed to be free from
operating defects; a scheduled maintenance chart for racing use is provided in
Section B.
* In order to maintain the vehicles Guarantee of Functionality, the client must

follow the maintenance programme indicated in Section B by having the required
maintenance inspections carried out at authorised HUSQVARNA dealers. The
Customer bears all part replacement and labour costs needed to respect the
maintenance schedule. In case of motorcycle hire the warranty becomes NULL
and VOID.
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.

b.2
GENERAL INFORMATION
CR 65 2012
Section

A.1
GENERAL INFORMATION
CR 65 2012
Engine...........................................................................................................A.3
Fuel system...................................................................................................A.3
Lubrication.....................................................................................................A.3
Cooling..........................................................................................................A.3
Ignition system..............................................................................................A.3
Kick . .............................................................................................................A.3
Primary drive.................................................................................................A.3
Gearbox.........................................................................................................A.3
Secondary drive............................................................................................A.3
Drive chain....................................................................................................A.3
Chassis..........................................................................................................A.3
Suspension....................................................................................................A.3
Brakes...........................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres..............................................................................................................A.4
Overall dimensions - Weight..........................................................................A.4
Electrical components location......................................................................A.5
Capacities......................................................................................................A.5

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

A.3
GENERAL INFORMATION
CR 65 2012
Brakes
Front
Type........................................................ with fixed disc Wave type 200 mm
hydraulic control and four piston fixed calliper.
Rear
Type........................................................ with fixed disc Wave type 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

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

A.5
MAINTENANCE
CR 65 2012
Section

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)

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 2012
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 2012
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.

B.3
MAINTENANCE
CR 65 2012
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

B.4
TROUBLESHOOTING
CR 65 2012
Section

C.1
TROUBLESHOOTING
CR 65 2012
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

C.2
Adjust
Replace
Replace
Clean
Replace
Replace
Replace
Tighten
TROUBLESHOOTING
CR 65 2012
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
Engine power lack

1.

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

C.3
TROUBLESHOOTING
CR 65 2012
CHASSIS
Trouble
The handlebar is hard to turn

Cause
Remedy
1. Tyre pressure insufficient
Inflate
2. Bearing adjuster ring nut or steering stem nut overtightened Adjust
3. Bent steering stem
Replace bottom yoke
4. Worn or seized steering bearings
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

C.4
TROUBLESHOOTING
CR 65 2012
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

C.5
SETTINGS AND ADJUSTMENTS
CR 65 2012
Section

D.1
CR 65 2012
Saddle removal.............................................................................................D.4
Tank removal.................................................................................................D.4
Remove the chain/sprocket cover protection casing.....................................D.5
Throttle cable adjustment..............................................................................D.5
Carburettor adjustment..................................................................................D.6
Idle adjustment..............................................................................................D.6
Front brake fluid level check . .......................................................................D.6
Clutch oil level check.....................................................................................D.7
Front brake lever adjustment.........................................................................D.8
Lever distance adjustment............................................................................D.8
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

D.2
CR 65 2012
CR 65

D.3
CR 65 2012
Saddle removal
Turn the rear pin (1) counterclockwise.
Release the saddle (2) from the front retaining screw pin.
Tank removal
Remove the saddle as described in the relevant paragraph.
Close the fuel cock (2) and loosen the clamp (3) on the hose running to the
carburettor. 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.
Slide the breather hose (7) out of the steering tube.

Remove the retaining screw (8) and then the tank (9).
7
8

D.4
CR 65 2012
Remove the chain/sprocket cover protection casing
Cut the ties (1) and remove the casing (2).

Loosen the 3 screws (3) that fasten the sprocket cover to the LH casing (4) and
remove the protection.
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;
- 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.
Exhaust gas contains poisonous carbon monoxide. Never run the engine
indoors.

D.5
CR 65 2012
Carburettor adjustment
Adjust the carburettor with warm engine and with the throttle control in closed
position. Proceed as follows:
- turn the idle speed adjuster screw (1) located on the left-hand side of the
vehicle, until setting idle RPM quite high (turn clockwise to increase the speed
and counter clockwise to reduce the speed).
- 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).
Front brake fluid level check
Check the front brake fluid level as follows:

- Stand the vehicle level and upright;
- Turn the handlebar so that the front brake master cylinder is in horizontal
position;
- Loosen the screws (1) and remove cover (2) together with diaphragm (3);
- Make sure the oil level is about 3 mm from the top edge, in case top-up with
oil of the type specified in the "LUBRICATION AND SUPPLIES" table.

D.6
CR 65 2012
A decrease of the fluid level will let air into the system, hence an extension of
the lever stroke.
If the brake lever feels mushy when pulled, there may be air in the brake
line or the brake may be defective: CHECK THE BRAKING SYSTEM
(see Section "L").
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
Check the clutch fluid level as follows:

- Stand the minicross level and upright;
- Loosen the screws (1) and remove cover (2) together with diaphragm (3);
- Make sure the oil level is about 3 mm from the top edge, in case top-up with
oil of the type specified in the "LUBRICATION AND SUPPLIES" table.
If the clutch feels mushy when pulled, there may be air in the brake line or
the brake may be defective: CHECK CLUTCH HYDRAULIC SYSTEM.
Do not spill brake fluid onto any painted surface or lens (for example
lights lens).
of contact, flush thoroughly with water and contact a doctor if your eyes
were exposed.

D.7
CR 65 2012
Front brake lever adjustment
Position adjustment
Loosen the screws (2) to adjust the lever (1) position.
When finished, tighten the screws (2) again.
Lever distance adjustment

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

D.8
CR 65 2012
Rear brake pedal position adjustment
The position of the rear brake pedal with respect to the footrest may be adjusted
according to individual needs.
For adjusting, proceed as follows:
- Loosen the screw (1).
- turn the cam (2) in order to raise or lower the brake pedal (3) within the range
available (A);
- 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.
0.2 in.
5 mm
Should this not happen, operate as follows:

- loosen nut (4);
- operate the pump rod (5) to increase or decrease the free play;
- tighten nut (4) at the end of the operation.
When the free play requirement is not met, the brake pads will be subjected
to an early wear that may lead to TOTAL BRAKE INEFFECTIVENESS.
If the brake pedal feels mushy when pulled, there may be air in the brake
line or the brake may be defective. CHECK THE BRAKING SYSTEM (see
Section L).

D.9
CR 65 2012
Rear brake fluid level check
The fluid level that can be seen through the inspection window (1) must be above
the minimum mark on the master cylinder tank.
To restore the level loosen the two screws (2), remove the cover (3), and top-up
with oil type specified in the "LUBRICATION AND SUPPLIES" table.
A decrease of the fluid level will let air into the system, hence an extension of
the lever stroke.
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).
of contact, flush thoroughly with water and call a doctor if your eyes were
exposed.

D.10
CR 65 2012
Oil level check
- Heat up the engine, then turn it off, wait 2 minutes for transmission oil to
properly widespread.
- Set the minibike on its stand so it is upright and level.
- Check the oil level is above the inspection window (1) lower edge.
If the oil level is low, top-up through the dedicated oil hole (2) located on
the casing upper side.
Oil replacement
Be careful not to touch hot engine oil.
Drain the oil with WARM ENGINE; proceed as follows:

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

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

D.11
CR 65 2012
Coolant level check
Check level (1) in right-hand radiator when engine is cold (place the motorcycle
so that it is perpendicular to the ground). The coolant should be approximately
0.39 in. above the cells.
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).
SLOWLY open the RH radiator cap (2); slope the motorcycle on the left side to
drain the coolant easily in the vessel.
Pour the necessary quantity of coolant in the radiator then warm up the engine
in order to eliminate any possible air bubbles.
Periodically check the connecting hoses (see Scheduled Maintenance Chart):

this will avoid coolant leakage and consequent engine seizure. If hoses (A) show
cracks, swelling or hardening due to sheaths desiccation, their replacement
shall be advisable.
Check the correct tightening of the clamps (B).

D.12
CR 65 2012
Air filter check and cleaning
- Remove the saddle as outlined in the relevant paragraph.
- Remove the plastic cover (1) by loosening the rear chassis retaining screw
(2). Release the spring (3) to remove the air filter (4).
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.
Never tamper the filter box cover: we strongly recommend not to remove
the material delimited by the cut to increase the air flow because this
would lead to a drastic decrease of performances at low and medium
rpm, against a very little improvement at high rpm; furthermore the cover
protects the filter against water, mud and dirt.
We recommend keeping a spare filter.

D.13
CR 65 2012
Chain adjustment
Chain should be checked, adjusted and lubricated as per the "Maintenance
Chart" (see Section B). to ensure safety and prevent excessive wear. If the chain
becomes badly worn or is poorly adjusted (i.e., if input and output shafts loose
or too taut), it could escape from sprocket or break.
Remove the chain protection casings as indicated in the relevant paragraph.
Place the minicross on a stand and insert a 25 mm drill rod (A) on the upper
chain guide.
Adjust the chain tension so that the drill rod passes freely without excessively
loosening the chain.
If it is not, proceed as follows:

- Loosen the hexagon nut (1).
- Loosen the check nuts (2) on both sides.
- Work on screw (3) on rear swinging arm both sides, to increase or decrease
the chain tension having care to centre the wheel in the rear swinging arm
referring to the notches on the swinging arm.
- When the desired tension is reached block the rear wheel shaft (4) by 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
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
4

D.14
CR 65 2012
Chain lubrication
Lubricate the chain following these instructions.
Never use grease to lubricate the chain. Grease helps to accumulate dust
and mud, which act as abrasive and help to rapidly wear out the chain,
the front and rear sprockets.
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 101 CLICKS. Turn clockwise to increase
the damping and vice versa.
Compression damping adjustment (LH fork leg)

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

Standard
10 clicks counterclockwise from end of travel
Compression damping (LH leg)

Standard
10 clicks counterclockwise from end of travel

D.15
CR 65 2012
Fork position adjustment
- Loosen the two screws (1) onto bottom yoke.
- Loosen the steering head screw (2).
- Adjust one fork leg at a time.
Refer to the notches on the leg upper part to adjust the fork position according
to the rider height and the riding needs.
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.
A
B
C
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.
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 2530 mm (0.98
1.18 in).
- Have bike resting on the ground with rider sitting on it;
Measure dimension "A";
and rider sitting on it shall be 6070 mm (2.36 2.76 in).
B: silencer retaining screw axle

C: rear wheel axle height

D.16
CR 65 2012
Shock absorber spring preload adjustment
Proceed as follows:
1. Remove the side panels as described in Section "E".
2. Loosen the two upper screws
(4) and remove the two lower screws (5)
that fasten the rear chassis to the frame.
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.
Be careful not to touch hot exhaust pipe while adjusting the shock absorber.
1
2
3
The standard length of the

pre-loaded spring is as
follows:
A= 217 1.5 mm

D.17
CR 65 2012
Shock absorber damping adjustment
It is possible to adjust the rebound travel of the shock absorber.
A) REBOUND - Standard setting: 2 turns (from fully closed)
To reset the standard setting, turn lower adjuster screw (1) clockwise until 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.
It is possible to adjust the compression travel of the shock absorber.

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

D.18
1 turn and counterclockwise from end of travel
CR 65 2012
Steering bearing clearance adjustment
For safety reasons, the steering should always be adjusted so that the handlebar
turns freely and without play. To check steering adjustment, set a stand or a block
under the engine and see that the front wheel is lifted from the ground. Press
lightly on the handlebar grips to cause the front end to rotate; the handlebar should
turn smoothly. Sit on the ground in front of the front wheel and hold the lower
ends of the fork legs. Push and pull in a front to rear motion to feel for play.
If any play is detected, adjust as follows:
- Loosen the screws (3) with a 6 mm wrench.

Loosen and retighten the nut (2) to a torque of 10 Nm - 1.0 Kgm - 7.38 ft/lb.
- Tighten the three screws (3) on the steering head to 25 Nm, 2.5 Kgm, 18.44
ft/Lb.
Handlebar position change
- Remove bumper (1) by cutting the two ties (2) that retain it to the handlebar.
- 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).

D.19
CR 65 2012
- Afterwards remove the lower ones (3) by loosening the relevant retaining
screws (4).
- Use one of the two holes (5) on the steering head to move the handlebar on
or back (of nearly 17 mm - 0.67 in.).
- 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.
- 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.
3
A
4

D.20
CR 65 2012
Tank supply and breather pipe check
Make sure the pipes (1) and (2) do not feature any leakage, cut, or evident
cracks, and in case replace them.
Replace the supply pipe (1) as described in section "E".
Exhaust system check
Remove exhaust system components as described in Section "E". Ensure that

pipe (1) and silencer (2) do not show any sign of failure or damage: replace if
cracked or damaged.
Check for any gas leakage between silencer end caps and central pipe (which
would indicate a wrongly carried out sealing).

D.21
CR 65 2012
Sound deadening material replacement
Remove the silencer (1) as described in the relevant paragraph and fasten it on
a suitable support (vice provided with aluminium protections) having care not
to deform the pipe.
Remove screws (2) that retain the rear end cap (3) and remove it from the
silencer body.
Slide out the external pipe and remove the worn/damaged sound deadening
material.
Clean the pipe damaged by any residue of burnt material and oil using first a
wire brush and a compressed air jet then.
Wrap the damaged pipe up in the new sound deadening material (5), paying
utmost attention.

D.22
CR 65 2012
Refit the external pipe having care to seal the front end cap with high-temperature
resistant silicone.
Apply some sealant (6) on the rear end cap too, and position the latter by starting
the retaining screws (2) WITHOUT TIGHTENING THEM COMPLETELY.
Once the silencer has been reassembled remove any surplus silicone.
Refit the silencer as described under the relevant paragraph; ONLY NOW tighten
the rear end cap screws to a torque of 9 Nm.

D.23
GENERAL PROCEDURES
CR 65 2012
Section

E.1
GENERAL PROCEDURES
CR 65 2012
Foreword.......................................................................................................E.3
Number holder removal ................................................................................E.4
Front mudguard removal ..............................................................................E.4
Saddle removal.............................................................................................E.5
Side panel removal . .....................................................................................E.5
Rear chassis with rear mudguard and air filter removal .................................E.6
Exhaust system removal ..............................................................................E.7
Fuel tank removal .........................................................................................E.9
Carburettor removal from the engine..........................................................E.10
Spark plug cap removal . ............................................................................E.10
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

E.2
GENERAL PROCEDURES
CR 65 2012
Foreword
This section describes the operations preliminary to engine removal.
Please note that, in order to gain access to certain motorcycle components (rear
shock absorber, electrical parts, wiring, etc.), it may be necessary to partially
remove some parts.
RIGHT-HAND SIDE
LEFT-HAND SIDE

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

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

E.4
GENERAL PROCEDURES
CR 65 2012
Saddle removal
- Turn the rear pin (1) counterclockwise.
- Release the saddle (2) from the front retaining screw pin.
Side panel removal

- Remove the saddle as described in the relevant paragraph.
- To remove the side panels of the vehicle it is necessary to first remove the
plastic cover (1) of the air box, loosening the rear chassis retaining screw
(2).
- Loosen the five retaining screws (3) and remove the left side panel (4).
- Proceed in the same way to remove the right side panel.
4
E.5
GENERAL PROCEDURES
CR 65 2012
Rear chassis complete with mudguard and air filter removal
- Remove the saddle as described in the relevant paragraph.
- Remove the side panels as described in the relevant paragraph.
- Slacken the clamp (1) that secures the rubber coupling (2) of the filter box
at the carburettor (3).
3
1
- Use an 8 mm ring wrench (screw) and a 10 mm wrench (nut) to remove the

screw and the nut to release the silencer from the rear chassis.
- Use a 12 mm ring wrench to remove the four retaining screws (4) from the
rear chassis on both sides.
- Remove the rear chassis with relevant mudguard and air filter (5) from behind
releasing the carburettor rubber fitting.
- For reassembly follow the removal procedure in the reverse order having
care to correctly fit the rubber fitting (2) on the carburettor so that it does not
intake unfiltered air.
- See section "X" for screw tightening torque figures.

E.6
GENERAL PROCEDURES
CR 65 2012
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
E.7
GENERAL PROCEDURES
CR 65 2012
- Remove the silencer (9) by sliding it from the rear side as shown in the figure.
Pay attention to the rubber connection coupling (8).
- Remove the springs (3) from the silencer (1).
- Use an 8 mm ring wrench to remove the screw (7) from the elastic support
fastened on the chassis.
- Remove the silencer (1).

E.8
GENERAL PROCEDURES
CR 65 2012
- Check conditions of gasket (2) and if damaged replace it.
For easier assembly smear some grease on the gasket (5).
- To reassemble, reverse the above procedure.

- See Section "X" for tightening torque figures.
Fuel tank removal
- 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.
- Turn the ring nut of the fuel cock (3) clockwise to shut off fuel supply and
loosen the clamp (4) on the hose running to the carburettor. Detach the hose
at carburettor end and let fuel drain into a pan.
- Remove the tank (5) by sliding it from the rear side as shown in the figure.

E.9
GENERAL PROCEDURES
CR 65 2012
Carburettor removal from the engine
- Loosen the tie (1) and remove the carburettor from the intake fitting.
Spark plug cap removal

- Take off the spark plug cap (1).
Radiator removal
- Remove the grids from the two radiators (1) releasing the pins from the holes
as shown in the figure.
- Before removing the radiator pipes, empty the cooling system by loosening
the screw (2) on the water pump cover.

E.10
GENERAL PROCEDURES
CR 65 2012
- Loosen the clamp (4) of the upper pipe that connects the RH radiator (the
pipe passes through the chassis).
If you need to remove the RH radiator with its connection pipe make sure to
keep the washer.
- 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).
6
- Remove the two screws (3) that retain the LH radiator to the chassis.
- Remove the LH radiator with head connection pipe (7).
To remove the RH radiator proceed as follows:

- Loosen clamp (1) that fastens the connection pipe (2) to the water pump.
1
E.11
GENERAL PROCEDURES
CR 65 2012
- Release the radiator breather hose (3) from the two chassis connection rubber clamps (4).
4
At this point, if the LH radiator had been previously removed, remove the two
screws (5) that fasten the radiator to the chassis by releasing the RH radiator
and the two pipes connecting it to the LH radiator, the pipe to the water pump,
and the breather hose on the plug.
Otherwise release the radiator from the two LH radiator connection pipes opening
the clamps (6) with the clic clamp pliers, and then disconnect it from the chassis
as described above.
Swinging arm removal
- Remove the plug (1) of the shaft nut (2) locking the swinging arm onto the
chassis.

E.12
GENERAL PROCEDURES
CR 65 2012
3
- After releasing the brake pedal (B) loosen the chassis retaining screw (4),
using a 17 mm socket wrench on the left, and a 14 mm one on the right to
remove the nut (2) of the swinging arm pivot (3) and the swinging arm (A)
itself.
Secondary drive chain removal

- Remove the case cover (1) to access the drive chain.
- Use needle-nose pliers to remove the master link (2) and open the drive
chain.
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.

E.13
GENERAL PROCEDURES
CR 65 2012
Generator cable disconnection
- Cut the tie (1) that retains the cables against the chassis. Disconnect the
generator electric cable connector (2).
Engine removal from the chassis

- Remove the two front screws (1) that retain the engine to the chassis.
- Remove the engine from the vehicle left side.

E.14
ENGINE DISASSEMBLY
CR 65 2012
Section

F.1
ENGINE DISASSEMBLY
CR 65 2012
Preparation.....................................................................................................F.3
Gearbox oil drainage procedure.....................................................................F.3
Cylinder head, cylinder and piston removal...................................................F.3
Water pump disassembly ..............................................................................F.4
Clutch cover removal......................................................................................F.5
Clutch disassembly........................................................................................F.5
Primary drive sprocket removal......................................................................F.6
Kick start pedal shaft removal........................................................................F.7
Gearbox control shaft and selector plate removal..........................................F.7
Intake flange and reed valve removal............................................................F.8
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

F.2
ENGINE DISASSEMBLY
CR 65 2012
Preparation
Clean the engine before disassembling it.
Fasten the engine into the installation stand.
Remove the kick start pedal and the gearbox lever.
Remove the gearbox breather pipe from the engine casing.
Gearbox oil drainage procedure

Remove the gearbox oil drainage screws (1) with relevant sealing ring and
drain the gearbox oil.
Cylinder head, cylinder and piston removal

Loosen the spark plug.
Remove all cylinder head screws (2) and the head itself.
3
4
Remove the two O-rings (3) from the cylinder grooves.

Remove both centring bushings (4).
Loosen the two clamps (5) and remove the water pipe.
Remove the exhaust pipe fitting (6) and its gasket by loosening the two
screws.
Remove the four flanged nuts from the cylinder base.
Carefully lift the cylinder up.

F.3
ENGINE DISASSEMBLY
CR 65 2012
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.
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.

F.4
ENGINE DISASSEMBLY
CR 65 2012
Clutch cover removal
Loosen the clutch cover screws to remove the cover and its gasket.
WARNING: When removing the clutch cover, pay attention to the thrust washer
(3) of the kick start pedal shaft (it may remain attached to the clutch cover and
the water pump shaft spring, page F4, spring (B)).
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.
Clutch disassembly
Place the retainer (1) on the hub and loosen the hexagonal-head screw.
Remove the hexagonal-head screw.

F.5
ENGINE DISASSEMBLY
CR 65 2012
Remove the plate pack (2) from the clutch housing.
WARNING: The plate pack consists of lined and steel plates, compression springs,
spring retaining plate with screws, pressure plate and hub.
If no repairing is required on the plate pack, then you do not need to continue
disassembling.
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).
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.
Remove the retaining tool, the hexagon nut, the lock washer and the primary
drive sprocket from the crankshaft.
Use the puller to remove the gear from the crankshaft.

F.6
ENGINE DISASSEMBLY
CR 65 2012
1
Kick start pedal shaft removal

Loosen the two screws (1) and remove the stop plate (2).
Remove the kick start pedal shaft from the casing.
Gearbox control shaft and selector plate removal

Use a screwdriver to push back the sliding plate (3) and at the same time
slide the gearbox control shaft out of the crankshaft.
Remove the screw (4) and slide the selector plate out of the selector drum.
Remove the circlip (5), the selector lever and spring.

F.7
ENGINE DISASSEMBLY
CR 65 2012
Intake flange and reed valve removal
Loosen the 4 screws (1) of the intake flange and remove the flange with
relevant reed valve and gasket.
Ignition system disassembly

Loosen the 3 screws of the ignition cover and remove the latter (1).
Hold the rotor and using the suitable wrench remove the flanged nut with its
elastic washer.
Screw the special puller (2) onto the rotor, keep the puller and by holding the
extraction screw slide the rotor out of the crankshaft.
Loosen the three screws (3) of the stator and remove the latter (4).
Remove the engine wiring ring from the crankcase.
Have care not to loose the key.

F.8
ENGINE DISASSEMBLY
CR 65 2012
Chain sprocket removal
Remove the circlip (1) and slide the chain sprocket out of the output shaft.
Slide the spacing bushing out of the output shaft using needle-nose pliers.
Splitting the crankcase

Turn up the ignition side and remove all screws from the casing.
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.
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.
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
WARNING:
The gearbox forks of the output shaft are the same, but despite that, they
should be refitted in the original position.For this reason mark them upon
disassembly.
The fork guiding rods are loaded by means of a spring, so it is recommendable
to slide them upwards from the gearbox forks. In this way the upper spring
remains in the rod and the lower one must be removed from the casing. Then
the gearbox forks can be moved aside.
MAKE SURE THE BUSHINGS DO NOT FALL FROM THE GEARBOX
FORKS.

F.9
ENGINE DISASSEMBLY
CR 65 2012
Process
Slide out the two gearbox shafts from the right crankcase half.
WARNING: when removing the two gearbox shafts pay attention to the output
shaft thrust washer which could be stuck inside the casing.
Crankshaft removal from casing

Use the two threaded rods to fasten the special tool (1) to the crankcase half
and pull the crankshaft out of the crankcase half.
WARNING: If the procedure described above is not possible, heat the crankcase
half up to nearly 100C.
Clean all parts, check them for wear and replace if necessary.
WARNING: In case of engine overhaul we recommend to replace all gaskets,
oil seals, O-rings and bearings.
UPON REMOVAL OF CRANKSHAFT HAVE IT KEPT BY ANOTHER
PERSON TO PREVENT IF FROM FALLING DOWN AND GETTING
DAMAGED.

F.10
ENGINE OVERHAUL
CR 65 2012
Section

G.1
ENGINE OVERHAUL
CR 65 2012
Engine crankcase (crankcase half)...............................................................G.3
Actions on left crankcase half........................................................................G.4
Actions on right crankcase half.....................................................................G.5
Crankshaft measurement..............................................................................G.6
Actions on clutch cover.................................................................................G.6
Water pump disassembly and inspection......................................................G.7
Piston check..................................................................................................G.8
Piston ring gap measurement.......................................................................G.8
Piston and cylinder measurement, piston assembly
clearance determination..........................................................................G.8
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

G.2
ENGINE OVERHAUL
CR 65 2012
Crankcase (crankcase half)
Warning: Carefully read this paragraph before starting the operation. Determine the reassembly sequence in order carry out a single
heating treatment on the crankcase halves to refit the bearings.
To detach or remove the bearings - if necessary even tapping with suitable tools - remove the reference bushings and place the 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.

G.3
ENGINE OVERHAUL
CR 65 2012
Actions on left crankcase half
Remove the oil seals and heat the crankcase half on an electric plate up to 150
C.
3
2
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.
Output shaft ball bearing (2)

Input shaft needle roller bearing (3)
Use a suitable 12-16 mm puller to remove the needle roller bearing from the
casing. Push the new needle roller bearing fully home.
Selector drum ball bearing (4)
Use a suitable puller to remove the roller bearing from the casing. Push the new
ball bearing fully home.
Engine oil seal (5)

From the outer side, force the new oil seal in with the sealing lip inwards.
Output shaft oil seal (6)
Gearbox control shaft oil seal (7).

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.

G.4
ENGINE OVERHAUL
CR 65 2012
Actions on right crankcase half
Remove the oil seals and heat the crankcase half on an electric plate up to 150
C.
2
6
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)
Input shaft ball bearing (2)

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

CASING TO AVOID DAMAGING THE LATTER.
Selector drum ball bearing (5)

Use a suitable punch to push the ball bearing from the outside.
Push the new ball bearing from the inside fully home.
Output shaft needle roller bearing (6)
Use a suitable punch to push the needle roller bearing from the outside.
Push the new needle roller bearing from the inside.
Engine oil seal (7)

8
7
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.

G.5
ENGINE OVERHAUL
CR 65 2012
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).

G.6
ENGINE OVERHAUL
CR 65 2012
Water pump disassembly and check
Loosen the three screws and remove the water pump with its seal.
Remove the circlip (1) and slide the water pump impeller out of the shaft.
Push the water pump shaft (2) inside together with the ball bearings to remove
it from the clutch cover.
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.
Screw the water pump cover with its seal on the clutch cover and tighten the
screws to 10 Nm.

G.7
ENGINE OVERHAUL
CR 65 2012
Piston check
Check what follows when reusing a piston:
1. Check for any dent or seizure on the piston sliding surface (you can use a
fine grain abrasive stone to remove light seizure signs).
2. Piston ring groove: The piston ring must not get stuck in the groove. To clean
the groove use an old piston ring or abrasive paper (grain 400).
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
50mm
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.

G.8
ENGINE OVERHAUL
CR 65 2012
WARNING:
When replacing piston and cylinder make sure they have the same marking.
The marking is on the piston crown and on the cylinder base.
The table below indicates the tolerance limits for the relevant components.
Always consider there must be an installation clearance of 0.065 mm!
MARKING
PISTON MEAS.
CYLINDER MEAS.
44.955 44.960 mm
45.025 45.030 mm
44.961 44.965 mm
45.031 45.035 mm
44.966 44.970 mm
45.036 45.040 mm
44.971 44.975 mm
45.041 45.045 mm
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.

G.9
ENGINE OVERHAUL
CR 65 2012
1
2
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
Selector (4)
Check wear on engagement points on the shaped selector plate.
Check the guiding pin fixed seat and wear.
Compression spring (5)

Check the compression spring pre-load for the sliding plate.
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.
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.

G.10
ENGINE OVERHAUL
CR 65 2012
6
1
2
5
LOXEAL
86-54
LOCTITE
243
Clutch check for component wear

Check for component wear:
Thrust bearing (1)
Clutch springs (2)
Minimum length 25 mm (when new 27 mm), if necessary replace all 6 springs.
6 lined plates (3)

The lined plates must be flat and feature a minimum thickness of 1.80 mm.
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.

G.11
ENGINE OVERHAUL
CR 65 2012
Kick start pedal shaft pre-assembly

Fasten the shaft (4) of the kick start pedal with the lower grooved side in the
vice (use protection jaws).
Insert the starting gear (5) with the stopping toothing down on the kick start
pedal shaft.
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
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.

G.12
ENGINE OVERHAUL
CR 65 2012
Input shaft assembly
Fasten the input shaft with the splined end down in the vice (use protection
jaws).
Properly oil all components before assembly.
Insert the 5th neutral gear (1) with the front couplings upwards, and fit the
circlip (2) with the sharp edge upwards.
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
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.

G.13
ENGINE REASSEMBLY
CR 65 2012
Section

H.1
ENGINE REASSEMBLY
CR 65 2012
Inserting the crankshaft in the engine casing............................................... H.3
Refitting the gearbox shafts and the gearbox control .................................. H.3
Crankcase halves coupling.......................................................................... H.4
Refitting the kick start pedal shaft ............................................................... H.4
Refitting the selector plate and the gearbox control shaft............................ H.5
Clutch assembly........................................................................................... 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

H.2
ENGINE REASSEMBLY
CR 65 2012
Inserting the crankshaft in the engine casing
Fasten the right crankcase half onto the installation stand.
Grease the crankshaft oil seal and oil the crankshaft ball bearing.
Fit the crankshaft installation tool with the relevant bushing (1) and insert the
crankshaft fully home.
UPON CRANKSHAFT INSERTION THE CONNECTING ROD MUST
BE FACED TO THE CYLINDER.
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.
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

H.3
ENGINE REASSEMBLY
CR 65 2012
Crankcase halves coupling
Remove the engine retainers on the installation stand.
Fit the two centring bushings in the right crankcase half.
Grease the oil seal of the input and output shafts.
The thrust washer 1 must not be fitted on the input shaft.
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.
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.

H.4
ENGINE REASSEMBLY
CR 65 2012
3
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.
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.

H.5
ENGINE REASSEMBLY
CR 65 2012
Refitting the primary drive sprocket
WARNING: Before fitting the primary drive sprocket it is necessary to degrease
the cone.
Degrease the crankshaft thread and smear some Loxeal 100 HSP.
Fit a new thrust washer and the hexagon nut.
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.

H.6
ENGINE REASSEMBLY
CR 65 2012
Refitting the clutch cover
Make sure that both centring bushings are fitted in the engine casing.
Smear some grease on the casing sealing surface and fit a new clutch cover
gasket.
Insert the thrust bearing 1 in the spring retaining plate.
Grease all clutch cover oil seals.
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
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).

H.7
ENGINE REASSEMBLY
CR 65 2012
Refitting reed valve and intake flange
Insert the reed valve with a new gasket in the engine casing, fit the intake
flange and fasten by means of 4 screws.
Fit the two remaining flanged screws on the cylinder base and tighten the 4
flanged screws to 18-20 Nm.
Screw the exhaust fitting and the gasket to the cylinder.

H.8
ENGINE REASSEMBLY
CR 65 2012
Refitting the ignition system and adjusting the fixed spark advance
Smear some Loxeal 24-18 on the three socket head screws thread and fasten
the stator (1) without tightening.
Smear some silicone in the cable ring and fit it in the relevant opening on the
casing.
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.
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.
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.

H.9
ENGINE REASSEMBLY
CR 65 2012
Cylinder head installation
Clean the cylinder and cylinder head sealing surfaces, and fit the O-rings (1)
in the relevant grooves (in case smear with some grease).
Remove both centring bushings (2).
Position the cylinder head with the water fitting back (intake side).
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.
Refitting the kick start pedal

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

H.10
ENGINE REASSEMBLY
CR 65 2012
Gearbox oil filling procedure
Screw the gearbox breather pipe to the engine casing.
Screw the gearbox oil bleeding screw (1) with its new sealing ring, and tighten
to 12 Nm.
Remove the oil filling screw from the clutch cover and fill in 0.50 l of gearbox
oil.
Refit the oil filling screw.

H.11
FRONT SUSPENSION
CR 65 2012
Section

I.1
FRONT SUSPENSION
CR 65 2012
Front suspension........................................................................................... I.3
Removing front fork....................................................................................... I.4
Fork spring features...................................................................................... I.5
Fork oil........................................................................................................... I.5
Cleaning the fork legs dust seals.................................................................. I.6

I.2
FRONT SUSPENSION
CR 65 2012
CR 65
Front suspension
Upside-down hydraulic fork with advanced axle (compression and rebound damping adjustment) with 35 mm legs.
The wheel travel on the forks axle is of 220 mm.

I.3
FRONT SUSPENSION
CR 65 2012
Removing front fork
Measure height "A" (it will need to be restored to original value on assembly). Set
a block under the engine and see that the front wheel is lifted from the ground
and then proceed as follows:
A
- Release the front brake hose and the engine stop cable from the hose ring
(1) inside the Number holder.
- Release the front brake hose from the U-bolt (2) that fastens the hose to the
left fork leg protection;

I.4
FRONT SUSPENSION
CR 65 2012
- Remove the brake calliper from the L.H. fork leg loosening the two retaining
screws (2);
- Remove the front wheel as described in Section "Y";
- Loosen the bolts (3) that secure the fork legs to steering head and bottom
yoke;
- Remove the fork legs.
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 2 mm
Level 100 2 mm (without spring, preload tube, and with tube fully home)
Oil quantity in each fork leg: 210 cu. cm

I.5
FRONT SUSPENSION
CR 65 2012
Cleaning the fork legs dust seals
Position the bike on a stand to lift up the front wheel, and push down the dust
seals protections on both fork legs.
The dust seals protections remove dirt from the fork legs that builds up
when using the vehicle, protecting the fork internal side. 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.
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.

I.6
REAR SUSPENSION
CR 65 2012
Section

J.1
REAR SUSPENSION
CR 65 2012
Rear shock absorber......................................................................................J.3
Rear suspension............................................................................................J.3
Removing the rear shock absorber................................................................J.4
Removing the chain rear casing.....................................................................J.4
Disassembling and servicing the swinging arm..............................................J.5
Servicing the swinging arm pivot....................................................................J.7
Servicing the rear rocker arm and suspension drop drag link........................J.7
Chain roller, chain guide, chain slider.............................................................J.8
Adjusting the shock absorber ........................................................................J.8

J.2
REAR SUSPENSION
CR 65 2012
Rear shock absorber
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.

J.3
REAR SUSPENSION
CR 65 2012
Rear shock absorber removal
- Remove the front retaining pin (1) of the drag link (2) of the suspension on the
chassis.
- Remove the shock absorber lower retaining screw (3) and the upper one (4),
and then slide the shock absorber (5) out.
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.
Removing the chain rear casing
- Remove the rear chain protection casing (1) by cutting the two ties (2) that
fasten it to the swinging arm.

J.4
REAR SUSPENSION
CR 65 2012
Disassembling and servicing the swinging arm
- Set a stand under the engine and see that the rear wheel is lifted from the
ground.
- Remove the secondary drive chain (1) and detach the rear brake line (2) from
the guide (A) on the swinging arm.
- 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.
3
- Slide the wheel (C) out.
- Remove the pin (5) that connects the shock absorber linkage to the swinging
arm (A).

J.5
REAR SUSPENSION
CR 65 2012
- Remove the plug (1) of the shaft nut (2) locking the swinging arm onto the
chassis.
- After releasing the brake pedal (B) loosen the chassis retaining screw (4),
using a 17 mm socket wrench on the left, and a 14 mm one on the right to
remove the nut (2) of the swinging arm pivot (3) and the swinging arm (A)
itself.
- 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.
2-3 =70 Nm / 7.1 Kgm / 51.63 ft/lb + Loctite 243

J.6
REAR SUSPENSION
CR 65 2012
Servicing the swinging arm pivot
Check shaft taper using a dial gauge. Place the shaft on two identical reference
blocks. Turn the shaft and move the dial gauge horizontally to determine the
amount of distortion.
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.
4
1
2
6

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
B
1
A
B
B
2
C
J.7
REAR SUSPENSION
CR 65 2012
3
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
2 Chain guide
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.
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.

and dimension "A" with the wheel on the ground shall be 2530 mm (0.98
1.18 in).
- Have bike resting on the ground with rider sitting on it;
and rider sitting on it shall be 6070 mm (2.36 2.76 in).
B: silencer retaining screw axle

C: rear wheel axle height

J.8
BRAKES
CR 65 2012
Section

L.1
BRAKES
CR 65 2012
Braking system.............................................................................................. L.3
Brake disc...................................................................................................... L.4
Checking brake pads for wear / replacing the pads...................................... L.5
Pads removal................................................................................................ L.5
Pads installation............................................................................................ L.5
Bleeding the front braking system................................................................. L.6
Bleeding the rear braking system.................................................................. L.7
Changing the fluid......................................................................................... L.8

L.2
BRAKES
CR 65 2012
Braking system
The braking system uses two independent circuits. Each system is equipped with
a brake calliper connected to a master cylinder with a fluid reservoir.
1. Front brake lever
2. Front brake master cylinder with fluid reservoir
3. 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
10
6
11

L.3
BRAKES
CR 65 2012
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.

L.4
BRAKES
CR 65 2012
Checking brake pads for wear / replacing the pads
Check brake pad wear.

Service limit A
- 1 mm (front and rear pads)
If service limit is exceeded, always replace the pads in pairs.
Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off
with alcohol any fluid or oil that inadvertently gets on the pads or disc.
Replace the pads with new ones if they cannot be cleaned satisfactorily.
FRONT
Pads removal
- 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.
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.
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

L.5
BRAKES
CR 65 2012
Bleeding the front braking system
A long travel and mushy feel of the brake lever indicate that there is air in the
system and the brake needs bleeding.
Bleeding procedure is as follows:
- Take the rubber cover off the bleed valve (1).
- 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.
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: 1216 Nm/ 1.21.6 Kgm/ 8.711.6 ftlb.
2
4
3 mm

L.6
BRAKES
CR 65 2012
Bleeding the rear braking system
A long travel and mushy feel of the brake pedal indicate that there is air
in the system and the brake needs bleeding.
Bleeding procedure is as follows:
- Remove the protection cap and connect a clear hose to the bleed valve (1) of
the calliper. 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.
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.
Bleed valve tightening torque: 1216 Nm/ 1.21.6 Kgm/ 8.711.6 ftlb

L.7
BRAKES
CR 65 2012
Changing the fluid
Brake fluid should be checked and changed as per the "Maintenance Chart" (see
page B.3) or earlier if contaminated with debris or water. Do not change brake
fluid in the rain or with a strong wind.
Use only fluid taken from a sealed container (DOT 4). Never reuse
brake fluid.
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.

L.8
BRAKES
CR 65 2012
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
2A

L.9
ELECTRICAL SYSTEM
CR 65 2012
Section

M.1
ELECTRICAL SYSTEM
CR 65 2012
Wiring diagram............................................................................................. M.3
Electrical components location..................................................................... M.4
Spark plug ................................................................................................... M.5
Handlebar switches...................................................................................... M.6
Left-hand switch........................................................................................... M.6
Ignition system resistance values - stator.................................................... M.6
Ignition coil................................................................................................... M.6
Ignition static parameters measurement with peak voltage adapter............ M.7
Important...................................................................................................... M.8

M.2
ELECTRICAL SYSTEM
CR 65 2012
Wiring diagram
black
Stop button
Pulsante
di arresto
Ignition
coil
Bobina
di accensione
ye-bl
orange
Generator
Generatore
blue-white
red-black
green-white
red-white
pick up
E
C
red-green
black
black
Cable colour
bk : black
bl : blue
gn : green
or : orange
re : red
ye : yellow
wh : white
M.3
ELECTRICAL SYSTEM
CR 65 2012
Electrical component location
The ignition system includes the following elements:
- Generator (1), on the inner side of L.H. crankcase half cover;
- Electronic ignition coil (2) under the tank on the chassis right side;
- Electronic control unit (3) on steering tube rake, behind the Number holder;

M.4
ELECTRICAL SYSTEM
CR 65 2012
Spark plug
The spark plug (4) is a "NGK" BR8 ECM spark plug. Check electrode gap "A"
(0.6 mm). A wider gap may cause difficulties in starting the engine and overload
the coil. A gap that is too narrow may cause difficulties when accelerating, when
idling or poor performance at low speed. 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 1012 Nm torque. Loosen the
spark plug then tighten it again to 1012 Nm. Spark plugs which have cracked
insulators or corroded electrodes should be replaced.

M.5
ELECTRICAL SYSTEM
CR 65 2012
Handlebar switches
Measure continuity on the different switches using a meter. Replace any part
found to be faulty.
Left-hand switch
1 Engine stop switch (1)
COLOUR
POSITION
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 +/- 60
CDI unit voltage supply: across green/red cable and black cable

Condenser charge coil: across black/red cable and green/white cable

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 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 +/- 1600 at 20 C
WARNING: it is not necessary to remove the ignition coil to take the

measurement.

M.6
ELECTRICAL SYSTEM
CR 65 2012
Ignition static parameter measurement with peak voltage adapter
Measurement conditions:
cold engine
remove the number holder
loosen the spark plug, connect it and keep it to ground
all connector couplings and connections to ground must be free of corrosion signs
for each measurement strongly press the kick start pedal at least 5 times
fully down.
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

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).


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)


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

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.

M.7
ELECTRICAL SYSTEM
CR 65 2012
IMPORTANT
Before washing the motorcycle, it is necessary to duly protect the following parts from water:
a) Rear opening of the muffler;
b) Clutch and front brake levers, handgrips, handlebar switches;
c) Air filter intake;
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.

M.8
ENGINE COOLING
CR 65 2012
Section

N.1
ENGINE COOLING
CR 65 2012
Coolant level check.......................................................................................N.3
Cooling circuit ...............................................................................................N.4
Engine cooling system overhaul . .................................................................N.5

N.2
ENGINE COOLING
CR 65 2012
Coolant level check
Coolant takes the heat from the piston-cylinder-and-head assembly and transfers
it to the radiator, where it is released to the atmosphere. Checking coolant level at
regular periods is critical to ensuring proper operation of the cooling system.
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

N.3
ENGINE COOLING
CR 65 2012
Cooling circuit
4
9
7
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

N.4
ENGINE COOLING
CR 65 2012
Servicing the engine cooling system
1
2
6
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

N.5
HYDRAULICALLY CONTROLLED CLUTCH
CR 65 2012
Section

P.1
CR 65 2012
Hydraulic clutch system..................................................................................P.3
Draining clutch fluid........................................................................................P.4
Servicing the clutch master cylinder...............................................................P.4
Filling/draining the clutch hydraulic system....................................................P.5

P.2
CR 65 2012
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.

P.3
CR 65 2012
Draining clutch fluid
Connect a plastic hose to the bleed valve and loosen the valve turning it back
by 1 or 2 turns. Remove reservoir cap and bellow diaphragm and operate the
control lever until draining all fluid.
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.

P.4
CR 65 2012
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.
- 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.

P.5
FUEL SUPPLY
CR 65 2012
Section

S.1
FUEL SUPPLY
CR 65 2012
Carburettor setting......................................................................................... S.3
Original setting..............................................................................................S.3
Main information about carburettor wear.......................................................S.3
Idle rpm A, Idle adjustment......................................................................... S.4
Valve opening B.......................................................................................... S.4
Partial load C.............................................................................................. S.4
Full load D.................................................................................................. S.4
Carburettor drawing....................................................................................... 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

S.2
FUEL SUPPLY
CR 65 2012
Carburettor setting
Original setting
The carburettor original settings are: 500 m altitude above sea level, temperature
of nearly 20 C, main use off-road and possibility of using premium grade fuel
in Central Europe (RON 95, without lead), mixed with 2T oil. Oil-fuel mixture
ratio at 3% during running-in phase, at 2% after running-in.
GENERAL RULE:
high altitudes or temperatures lean mixture
low altitudes or temperatures 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

S.3
FUEL SUPPLY
CR 65 2012
Idle rpm A, Idle adjustment
Operation with closed throttle valve. This rpm is controlled by the position of
the air adjuster screw (1) and the throttle valve stop screw (2).
Any adjustment shall be carried out with warm engine only.
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.
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.

S.4
Tapermassimo
needle
Getto
Spillo conico
maximum
jet
Spillo
Taper
needle
conico
B
A
Minimum
jet
Getto
minimo
valve
Valvola
Minimum
jet
Getto minimo
FUEL SUPPLY
CR 65 2012
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
S.5
FUEL SUPPLY
CR 65 2012
Removing and refitting the carburettor
WARNING: before acting on the carburettor, thoroughly clean the motorcycle.

Close the fuel cock (1) and remove the pipe (2) from the carburettor.
Remove the clamp (3) and release the carburettor breather pipes from the
transmission oil breather pipe.
Loosen the two screws (4).
Remove the cover (5) of the carburettor together with the throttle valve.

S.6
FUEL SUPPLY
CR 65 2012
6
Loosen the clamp (6) on the filter box connection unions.
Remove saddle and side panels as described in Section "E".
Disconnect the silencer from the rear chassis supporting plate.

Remove the two lower screws (7) and loosen the two upper screws (8) that
connect the rear chassis to the front chassis.
Turn the rear chassis (9) to completely release the carburettor from the union
(10) that connects the air filter.
10
Loosen the tie (11) and remove the carburettor from the intake fitting.
11

S.7
FUEL SUPPLY
CR 65 2012
Disassembling the carburettor
WARNING: Before starting disassembling the carburettor, prepare and clean the
working area. Such area should be sufficiently big to arrange in an orderly way
all carburettor single components.
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.
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

S.8
FUEL SUPPLY
CR 65 2012
Remove the idle adjusting screw (8) together with the spring.
Screw the air adjuster screw (1) fully home counting and recording the
turns.
Remove the air adjuster screw, the spring, the washer and the O-ring.
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.
The piston (4) must not feature evident scratching or deposits.

S.9
FUEL SUPPLY
CR 65 2012
Checking the taper needle and throttle valve
Check that the taper needle (3) is not worn out or deformed.
Because of the engine vibrations the throttle valve, the floater taper needle, and
the main nozzle are subject to high wear. Wear causes carburettor 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.

S.10
FUEL SUPPLY
CR 65 2012
Emptying the carburettor bowl
Close the fuel cock and place a cloth under the carburettor able to absorb
fuel flowing out.
Open the closure screw 1, have the residual fuel flowing into the bowl, and
clean the closure screw with compressed air.
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.
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

S.11
SPECIAL TOOLS
CR 65 2012
Section

W.1
SPECIAL TOOLS
CR 65 2012
SPECIAL TOOLS

HUSQVARNA CODE
DESCRIPTION
1 8000 H7677
Crankshaft removing tool
2 Commercial
Bearing puller
3 Commercial
Insert for bearing puller 12 - 16 mm
4 8000 H7678
Primary gear retainer
5 Commercial
Flywheel and clutch retainer
6 8000 H7679
Spark advance adjusting gauge
7 8000 46613
Flywheel puller
8 Commercial
Puller
9 Commercial
Pliers for cooling system clamps
6
ignition
cylinderheight

W.2
CR 65 2012
Section
Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might
become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might
become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening
torque figures for the most important nuts and screws, which have determined in accordance with thread diameter, pitch and
specific application. These figures are obtained after cleaning the threads with solvent.

X.1
CR 65 2012
CHASSIS
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
NOTES
Chain roller to chassis retaining screw
M8
25
LOCTITE 243
Front low. and upp. engine retaining screw
M8
35
LOCTITE 243
Engine lock nut
M8
35
LOCTITE 243
Rear chassis to chassis connecting screw
M8
25
Stand support upper retaining screw
M6
10
Coil to chassis retaining screw
M6
10
Saddle engagement plate retaining screw
M8
Saddle to tank retaining screw
M6
DESCRIPTION
LOCTITE 243
HANDLEBAR AND CONTROLS

MEASURE
Qty
NOMINAL
TORQUE
(Nm)
Check nut for lug adjustment
M6
10
Lever joint retaining screw
M6
10
LOCTITE 243
Brake lever to chassis retaining screw
M10
35
LOCTITE 243
Cam retaining screw
M6
10
Front brake hose clamp to fork retaining screw
M5
Front brake hose clamp to fork retaining nut
M5
Gear shift pedal retaining screw
M6
10
Clutch protection retaining screw
M6
10
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
U-bolt to steering head retaining screw
M10
35
U-bolt closing screw
M8
28
Fork plate retaining TORX screw
M8
25
Fork guard to fork bottom retaining screw
M6
DESCRIPTION
NOTES
FRONT SUSPENSION
DESCRIPTION
Steering upper nut
10
1 Nm = 0.73756 ft/lb

X.2
NOTES
CR 65 2012
REAR SUSPENSION
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
Chain slider on fork retaining screw
M5
Rear chain guide retainers
M6
10
Shock absorber to chassis retaining screw
M10
70
LOCTITE 243
Shock absorber to rocker arm retaining screw
M10
50
LOCTITE 243
Shock absorber low. and upp. lock nut
M10
50
LOCTITE 243
Drag link to chassis connecting screw
M12
70
Drag link to rocker arm connecting screw
M12
70
Rocker arm to swinging arm connecting screw
M12
70
Rocker arm screws retaining nut
M12
70
LOCTITE 243
Swinging arm pivot retaining nut
M12
70
LOCTITE 243
DESCRIPTION
Rear brake hose ring retaining self-threading screw
NOTES
MUDGUARD FAIRINGS
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
Front mudguard retaining screw with collar
M6
Number holder retaining screw with collar
M6
1.5
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
Side panel to rear chassis and tank retaining screw with collar
M5
Side panel front retaining screw with collar
M6
Filter box cover retaining screw with collar
M5
Clip nut
M5
Wheelhouse to rear chassis front retaining screw
M6
Wheelhouse to rear chassis retaining screw
1.5
Wheelhouse to rear mudguard connection screw
1.5
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

X.3
CR 65 2012
SUPPLY SYSTEM
DESCRIPTION
Tank front retaining screw
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
M6
1.5
Cock retaining self-threading screw
NOTES
WHEELS AND BRAKES

MEASURE
Qty
NOMINAL
TORQUE
(Nm)
NOTES
Front brake disc retaining screw
M6
10
LOCTITE 243
Front wheel axle retaining screw
M10
45
Front wheel axle to fork retaining screw
M6
10
Rear brake disc retaining screw
M6
10
Sprocket retaining nut
M8
35
Rear wheel axle
M12
85
Rear wheel retaining nut
M12
85
Chain tensioner adjusting screw
M6
Chain tensioner and adjusting nut
M6
Front brake calliper retaining screw
M8
25
LOCTITE 243
Rear brake calliper retaining screw
M8
25
LOCTITE 243
Rear brake master cylinder retaining screw
M6
10
LOCTITE 243
Rear brake master cylinder retaining nut
M6
10
LOCTITE 243
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
NOTES
Vibration damper to chassis retaining screw
M6
10
Vibration damper to chassis retaining nut
M6
10
Vibration damper to silencer retaining screw
M6
10
Silencer to bracket retaining nut
M6
10
Silencer to bracket retaining screw
M6
10
Rear chassis to bracket retaining screw
M5
Silencer end cap retaining screw
M5
DESCRIPTION
LOCTITE 243
EXHAUST
DESCRIPTION
1 Nm = 0.73756 ft/lb

X.4
CR 65 2012
COOLING SYSTEM
MEASURE
Qty
NOMINAL
TORQUE
(Nm)
Radiator retaining screw
M6
10
Radiator retaining flanged lock nut
M6
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
4850 Nm
4.895.10 Kgm
35.436.88 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
1012 Nm
1.021.22 Kgm
7.48.9 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)

X.5
CR 65 2012
INSTALLATION TOLERANCES AND CLEARANCES
Crankshaft ...................................................................max. drive shaft axes misalignment
0.050 mm
Handwheel external measure . ....................................
57 mm +/- 0.05 mm
Connecting rod big end bearing ..................................max. radial clearance
0.030 mm
Max. piston pin ............................................................radial clearance
0.03 mm
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
Gearbox shafts.............................................................axial clearance
0.10 - 0.20 mm
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
M5
4 Nm
0.4 Kgm
3 ft/lb
M5
4 Nm
0.4 Kgm
3 ft/lb
M5
6 Nm
0.6 Kgm
4.4 ft/lb
M6
6.5 Nm
0.65 Kgm
4.8 ft/lb
M6
6.5 Nm
0.65 Kgm
4.8 ft/lb
M6
10.5 Nm
1 Kgm
7.7 ft/lb
M8
16 Nm
1.6 Kgm
11.8 ft/lb
M8
26 Nm
2.6 Kgm
19.1 ft/lb
M10
52 Nm
5.2 Kgm
38.3 ft/lb
M12
100 Nm
10 Kgm
73.8 ft/lb
M14
145 Nm
14.5 Kgm
107 ft/lb

X.6
CHASSIS AND WHEELS
CR 65 2012
Section

Y.1
CHASSIS AND WHEELS
CR 65 2012
Chassis.......................................................................................................... Y.3
Lubrication points (lubricant)......................................................................... Y.3
Front wheel.................................................................................................... Y.4
Front wheel removal...................................................................................... Y.5
Front wheel installation.................................................................................. Y.6
Rear wheel.................................................................................................... Y.7
Rear wheel removal...................................................................................... Y.8
Wheel servicing............................................................................................. Y.9
Wheel axle warpage...................................................................................... 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

Y.2
CHASSIS AND WHEELS
CR 65 2012
Chassis
The single frame branches off at the exhaust and is made of steel tubes with circular, rectangular and ellipsoidal section; the rear
chassis is made from light alloy.
A badly damaged chassis must be replaced.
Lubrication points (lubricant)

1 Steering bearings (grease)

Y.3
CHASSIS AND WHEELS
CR 65 2012
Front wheel
Light alloy wheel hub and rim with high-strength steel spokes.
Make, type and size of light alloy wheel rims: 1.6x14

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

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

Y.4
CHASSIS AND WHEELS
CR 65 2012
Removing the front wheel
Set a stand under the engine and see that the front wheel is lifted from the
ground.
Loosen the screw (1) placed on the left side;
Loosen the two screws (2) that fasten the pin head to the fork bottom on the
right side;
Slide the pin (3) out from the right side and remove the wheel having care to
recover the two spacers (one for each side).
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.

Y.5
CHASSIS AND WHEELS
CR 65 2012
Reassembling the front wheel
Fit the wheel between the fork legs so as to set the brake disc into the calliper.
Working on right side, push the previously-greased wheel axle (3) all the way down,
tapping it on left fork leg; during this operation, the wheel should be turned.
Tighten the two screws (2) that retain the pin head to the fork.
Tighten the screw (1) on the fork L.H.
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

Y.6
CHASSIS AND WHEELS
CR 65 2012
Rear wheel
Light alloy wheel hub and rim with high-strength steel spokes.

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

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

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

Y.7
CHASSIS AND WHEELS
CR 65 2012
Removing the rear wheel
Set a stand under the engine and see that the rear wheel is lifted from the
ground.
Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to
loosen the chain tensioners (2); in this way, the chain tension will remain unchanged after reassembly.
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.
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.
After reassembly, depress the brake pedal until the pads are against
the brake disc.
1: 85 Nm/ 8.7 Kgm/ 62.73 ft/lb

Y.8
CHASSIS AND WHEELS
CR 65 2012
Wheel servicing
Check the wheel hub bearings for wear. If you find too much (radial or axial)
clearance, replace the bearings as follows:
- place the hub on a flat surface with an appropriate hole (for when you knock
out the bearing);
- 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.)

Y.9
CHASSIS AND WHEELS
CR 65 2012
Wheel spokes
Make sure all nipples are firmly tightened (4.4 Nm, 0.45 Kgm, 3.2 ft/lb). Retighten
if needed. Improper tightening will affect motorcycle stability; for a quick check,
simply tap the spokes with the tip of a metal tool (such as a screwdriver): a clear,
crisp sound indicates proper tightening, a dull sound means that the spokes
need to be tightened.
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

Y.10
2 mm (0.078 in.)
CHASSIS AND WHEELS
CR 65 2012
Rear chain sprocket, secondary drive sprocket and chain
The figure at the side shows the profiles of a normally worn and an exceedingly
worn sprocket.
1 Normal wear
2 Exceeding wear
If the sprocket is exceedingly worn, replace it after loosening the five screws
that retain it to the hub.
Chain and sprockets must always be replaced as a set.

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

Y.11
CHASSIS AND WHEELS
CR 65 2012
Checking sprocket wear
Check the transmission sprocket for damage or wear. When worn down like the
sprocket shown in the figure, it must be replaced.
Wheel misalignment causes abnormal wear, making the motorcycle
unsafe to ride.
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.

Y.12

Repair Manual Husqvarna CR 65 2012

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CR 65 2012

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FOREWORD, TABLE OF CONTENTS

1. Chassis serial number

Workshop Manual Ed. 09-2011

FOREWORD, TABLE OF CONTENTS

Accident-prevention rules for operator and persons working nearby.

Additional information concerning the operation covered in the text.

Workshop Manual Ed. 09-2011

FOREWORD, TABLE OF CONTENTS

Workshop Manual Ed. 09-2011

Workshop Manual Ed. 09-2011

* In order to maintain the vehicles Guarantee of Functionality, the client must

Workshop Manual Ed. 09-2011

Workshop Manual Ed. 09-2011

Workshop Manual Ed. 09-2011

Workshop Manual Ed. 09-2011

243 mm (9.57 inch)

1130 mm (44.49 inch)

Kerb weight, without fuel......................................................... 56.8 kg (125.2 lb)

Workshop Manual Ed. 09-2011

750 mm (29,53 inch)

1015 mm (39.96 inch)

*770 mm (30.31 inch)

230 mm (9.06 inch)

Front fork oil

CASTROL SYNTHETIC FORK OIL - 5W

Cooling system fluid

CASTROL MOTORCYCLE COOLANT

IMPORTANT - Do not add any additives to fuel or lubricants

Workshop Manual Ed. 09-2011

Workshop Manual Ed. 09-2011

Transmission oil level check

Transmission oil change

Carburettor fastening on intake manifold 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

Spark plug check and/or replacement, electrode gap adjustment

Carburettor cleaning and adjustment

Fork complete maintenance *

Shock absorber maintenance *

Swinging arm support and bearing cleaning and greasing *

Steering bearings and relevant sealing elements cleaning and greasing *

Brake/clutch fluid replacement *

Brake level, pad thickness, brake disc check

Brake pipe status check

Front lever and brake pedal adjustment and operation check

Braking system screw tightening check

Exhaust system check

Air filter and filter box cleaning

Shock absorber and fork operation check