125-200cc looking for a guide to replacing piston - wr125

Hi all,

Is there a guide to replacing a piston kit on a 2006 wr125?
the owners manual doesnt really go into detail, is there a better manual out there?

If you have just the standard owners manual then look for a shop manual. Halls Cycle sells them on CD for 10 or 20 bucks. Thats what I bought for my '09 so they should have them for an '06. There was also a member on here that had downloaded different year and model shop manuals to a thread. I dont have the link but maybe someone else does. It might actually be a sticky. Or just search for it. It shouldnt be too hard to find.

Ive had a search but didn't come up with anything

Just had a look on halls cycles website too but can't seem to find any manuals?
do they have an ebay shop?
im from the UK so i don't even know if they would post.....

There's a husky dealer in my town, so it may be worth asking them to see if they can get hold of one for me... but if anyone can find the guide it would be a massive help!

Cheers

Use this as guide and im sure you cant go wrong! although you may not want to remove the head
A good guide for all the less mecanical minded amongst us
http://www.cafehusky.com/threads/tear-down-and-install-procedure-for-wb165-kit.23885/

I'm in Italy with crap internet so I can't confirm, but I believe this is where to get the 06 manual:
http://www.husqvarnaoutlet.com/repair_manuals

Thanks for the reply's guys, that guide looks spot on! exactly what i was after

Erigre i downloaded that manual but its more of an owners manual and doesn't go into details with the engine, just mentions go to your local husky dealer!

I will be popping into my dealer in the next few days, hopefully they might give me a freebie as ive given them 10 hours of work on a mates bike, but we will see :P
if i get one ill try and get it uploaded for us all if its not huge!

Ive also dropped husky sport a message to see how much there piston kit is

Sorry about that. Could not remember and could not confirm.
I have found a big group of old (up to 04) repair manuals and
the 08 cr125 and 11 wr/cr 125-150 manuals by searching around
in the past. Have them on my HD at home, but poor connection
here in Italy and can't access my iDisk which also has them.
The 125-165 guide that Matt posted is all you really need though.
Once you do it, you'll see it's pretty straightforward.
Send me a pm for more info if you need it.

Thankyou! The guide looks great.

I know when i undo the head bolts i need to do it in a star formation, so i do not crack/warp the head.

When it comes to re-tightening these bolts up, do you know how tight they need to be torqued up?

Ill have a look at it tonight so will hopefully have a few photo's once its off for people's opinions on the condition of barrel etc

You dont really even have to remove the head just the four 12mm nuts that hold the barrel on, it all depends how involved you want to make the job ie checking ring gap/ removing any carbon ect
I personaly would pull the whole lot in one bit and go from there and remove the head if only nessersary

Here is a guide with pictures I made when I put a piston in my 06.

http://www.thumpertalk.com/topic/62...iston power valve__fromsearch__1#entry6105908

Great guide NWRider thanks, that will come in useful when i put the new piston in!
When i removed the PV cover i noticed that the plastic link arm wasnt connected at the top, i may have knocked it but im pretty sure it was disconnected already.... hopefully this is the casue of the mid and top range bog ive been having!

Ive got the barrel and head off, piston looks ready for a change but the barrel looks in good condition.

It does seem glazed though, i cant really see any honing marks so do you think it needs a re-hone?

Chris

The PV are takes a good bit of force to pry off so I am sure you did not knock it off. That would sure make the bike not run well. You want to make sure the power valves open and close freely while you are in there.

Thankyou buddy, the pv opens and closes nicely, ill give them a good cleanout while i have the barrel off, should i just use some carb cleaner?