125-200cc Service Manual for 09 Wr125

Does anyone have the torque values for all the bolts on a 09 WR125 and also any pages showing the top end and power valve adjustment?

The new manual doesn't have hardly anything in it. I had to print the manual for the 50mm forks from Marzocchi site.

Thanx!

I'm looking for one for my '06 WR 125 also. I had just found one for my 610 online but still need one for my 125.

I have one for an 08 but it is not what you would expect from a true indepth service manual. I will see if I can copy and post all the torque specs because those will be the same.

Walt

Applicazione Filettatura
Application Threading
Application Filetate Nm Kgm Lb/ft
Prigioniero fiss. testa cilindro
Stud bolt fixing head and cylinder M8x1,25 (*) 19,6÷21,6 2,0÷2,2 14,5÷15,9
Prisonnier de fixation cylindre
Dado fiss. cilindro
Nut fixing the cylinder M8x1,25 17,6÷19,6 1,8÷2,0 13,0÷14,5
Ecrou de fixation cylidre
Vite fiss. piastrina cuscinetto basamento
Screw fixing base bearing plate M6x1 (*) 7,9÷8,7 0,81÷0,89 5,8÷6,4
Vis de fixation plaque palier soubassement
Prigioniero ant. fiss. cilindro
Front stud bolt fixing cylinder M8x1,25 (*) 19,6÷21,6 2,0÷2,2 14,5÷15,9
Prisonnier avant de fixation cylindre
Prigioniero post. fiss. cilindro
Rear stud bolt fixing cylinder M8x1,25 (*) 19,6÷21,6 2,0÷2,2 14,5÷15,9
Prisonnier arrière de fixation cylindre
Vite fiss. piastrina cuscinetto albero primario
Screw fixing main shaft bearing plate M5x0,8 5,1÷5,7 0,52÷0,58 3,8÷4,2
Vis de fixation plaque palier arbre moteur
Vite fiss. inserto albero motore
Screw for fixing the main shaft insert M5x0,8 9.8 1 7.2
Vis de fixation insert de l’arbre moteur
Vite fiss. leva distribuzione
Screw for fixing the timing system levers M5x0,8 5.9 0.6 4.3
Vis de fixation leviers de la distribution
(*): “LOCTITE 243”
(*): “

Applicazione Filettatura
Application Threading
Application Filetate Nm Kgm Lb/ft
Dado fiss. mozzo frizione
Nut fixing clutch hub M16x1 27,4÷30,4 2,8÷3,1 20,2÷22,4
Vis de fixation moyeu embrayage
Vite fiss. molla frizione
Screw fixing clutch spring M6x1 7÷7,7 0,71÷0,79 5,1÷5,7
Vis de fixation ressort embrayage
Vite fiss. leva avviamento
Screw fixing starter lever M6x1 8,8÷9,8 0,9÷1,0 6,5÷7,2
Vis de fixation levier de démarrage
Vite fiss. perno avviamento
Screw for fixing the start pin M6x1 9.8 1 7.2
Vis de fixation goujon de démarrage
Vite fiss. rocchetto com. cambio
Screw fixing gearbox sproket M5x0,8 (**) 5,1÷5,7 0,52÷0,58 3,8÷4,2
Vis de fixation couronne de commande boite des vitesses
Vite fiss. bussola com. cambio
Screw fixing gearbox bush M6x1 (*) 8,8÷9,8 0,9÷1,0 6,5÷7,2
Vis de fixation douille de commande boite des vitesses
Vite fiss. leva cambio
Screw fixing gearbox lever M6x1 8,8÷9,8 0,9÷1,0 6,5÷7,2
Vis de fixation levier boite des vitesses
Dado fiss. pignone pompa acqua
Nut fixing water pump pinon M12x1 46,6÷51,4 4,8÷5,2 34,6÷37,6
Ecrou de fixation pignon pumpe à eau
Vite fiss. superiore telaio posteriore
Nut fixing upper rear frame M8x1,25 24,5÷26,5 2,5÷2,7 18,1÷19,5
Ecrou de fixation supérieur cadre arrière
Vite fiss. inferiore telaio posteriore
Nut fixing lower rear frame M8x1,25 24,5÷26,5 2,5÷2,7 18,1÷19,5
Ecrou de fixation inférieure cadre arrière
Vite fiss. rullo catena
Nut fixing chain roller M8x1,25 25,5÷28,5 2,6÷2,9 18,8÷21
Ecrou de fixation rouleau chaíne
Vite fiss. anteriore motore
Nut fixing engine front M8x1,25 33,3÷37,3 3,4÷3,8 24,5÷27,5
Ecrou de fixation avant moteur
Vite fiss. inferiore motore
Nut fixing engine low side M8x1,25 33,3÷37,3 3,4÷3,8 24,5÷27,5
Ecrou de fixation inférieur moteur
Vite rotazione cavalletto laterale (WR)
Screw for rotation of side stand (WR) M8x1,25 () 11,7÷11,9
1,19÷1,21 8,60÷8,75
Vis de rotation béquille latérale (WR)
Vite fiss. piastra attacco sup. motore al telaio
Screw for fixing the plate for upper connection to the frame M8x1,25 24,5÷26,5 2,5÷2,7 18,1÷19,5
(*) “LOCTITE 243” (**) “LOCTITE 270” () “LOCTITE 242”

Applicazione Filettatura
Application Threading
Application Filetate Nm Kgm Lb/ft
Vite fiss. superiore motore
Screw fixing engine upper side M8x1,25 24,5÷26,5 2,5÷2,7 18,1÷19,5
Vis de fixation supérieure moteur
Vite fiss. cavallotto freno anteriore
Screw fixing front brake connection M6x1 4,7÷5,1 0,48÷0,52 3,5÷3,8
Vis de fixation crampillon frein avant
Vite fiss. tubazione freno ant. sulla pompa freno 18,1÷20,1 1,85÷2,05 13,4÷14,8
Screw for fixing the front brake pipes on brake pump M10x1
Vis de fixation tuyauterie frein avant sur la pompe frein 23,5÷25,5 2,4÷2,6 17,3÷18,8
Vite fiss. cavallotto frizione
Screw fixing clutch connec tion M6x1 4,7÷5,1 0,48÷0,52 3,5÷3,8
Vis de fixation crampillon embrayage
Vite fiss. pedale freno posteriore
Screw fixing rear brake pedal M10x1,25 (*) 39÷44 4,0÷4,5 29÷32,5
Vis de fixation pédale frein arrière
Vite fiss. pompa freno posteriore
Screw fixing rear brake pump M6x1 9,8÷10,8 1,0÷1,1 7,2÷8,0
Vis de fixation pompe frein arrière
Vite fiss. serbatoio fluido freno
Screw fixing brake fluid tank M6x1 2,35÷2,55 0,24÷0,26 1,73÷1,88
Vis de fixation reservoirs fluide des freins
Vite fiss. tubazione freno posteriore
Screw fixing rear brake pipe M10x1 18,1÷20,1 1,85÷2,05 13,4÷14,8
Vis de fixation tuyauterie frein arrière
Interruttore stop posteriore (WR)
Rear light switch (WR) M10x1 13,8÷15,7 1,4÷1,6 10,1÷11,6
Interrupteur feux de stop (WR)
Vite fiss. perno ruota anteriore
Screw fixing front wheel axle M10x1,5 49÷55 5,0÷5,5 36,2÷39,8
Vis de fixation pivot roue avant
Vite fiss. steli forcella
Screw fixing forkrods M8x1,25 23,5÷25,5 2,4÷2,6 17,3÷18,8
Vis de fixation tiges fourche
Ghiera reg. cuscinetti sterzo (1° avvitamento)
Ring nut for handlebar bearing adjustment (1st turn) M25x1 3,2÷3,6 0,33÷0,37 2,4÷2,7
Collier de réglage paliers de direction (1ère vissage)
Dado perno di sterzo
Nut for handlebar pin M24x1 79÷87 8,1÷8,9 58÷64
Ecrou pivot de direction
Vite fiss. camma regolazione pedale freno
Screw for fixing the brake pedal adjusting cam M6x1 18,1÷20,1 1,85÷2,05 13,4÷14,8 Vis de fixation came de réglage pédale du frein
WR
CR
(*): “

How's that for unreadable,
Walt

for the 2006 you can try here

http://www.husqvarnaoutlet.com/repair_manuals

Has anyone found a 2009 WR 125 service manual?

Try calling Halls. I just got one for my WR250 from them.

Thanks Wallybean for the settings. I cleaned it up a bit. Now if I can just figure out what the Italian to English translated parts are...





WR 125 2009 Torque Settings

Application / Bolt Size / Nm / Kgm / Lb/ft

Stud bolt fixing head and cylinder / M8x1.25 (*) / 19.6-21.6 / 2.0-2.2 / 14.5-15.9
Nut fixing the cylinder / M8x1.25 / 17.6-19.6 / 1.8-2.0 / 13.0-14.5
Screw fixing base bearing plate / M6x1 (*) / 7.9-8.7 / 0.81-0.89 / 5.8-6.4
Front stud bolt fixing cylinder / M8x1.25 (*) / 19.6-21.6 / 2.0-2.2 / 14.5-15.9
Rear stud bolt fixing cylinder / M8x1.25 (*) / 19.6-21.6 / 2.0-2.2 / 14.5-15.9
Screw fixing main shaft bearing plate / M5x0.8 / 5.1-5.7 / 0.52-0.58 / 3.8-4.2
Screw for fixing the main shaft insert / M5x0.8 / 9.8 / 1 / 7.2
Screw for fixing the timing system levers / M5x0.8 / 5.9 / 0.6 / 4.3
Nut fixing clutch hub / M16x1 / 27.4-30.4 / 2.8-3.1 / 20.2-22.4
Screw fixing clutch spring / M6x1 / 7-7.7 / 0.71-0.79 / 5.1-5.7
Screw fixing starter lever / M6x1 / 8.8-9.8 / 0.9-1.0 / 6.5-7.2
Screw for fixing the start pin / M6x1 / 9.8 / 1 / 7.2
Screw fixing gearbox sprocket / M5x0.8 (**) / 5.1-5.7 / 0.52-0.58 / 3.8-4.2
Screw fixing gearbox bush / M6x1 (*) / 8.8-9.8 / 0.9-1.0 / 6.5-7.2
Screw fixing gearbox lever / M6x1 / 8.8-9.8 / 0.9-1.0 / 6.5-7.2 /
Nut fixing water pump pinion / M12x1 / 46.6-51.4 / 4.8-5.2 / 34.6-37.6
Nut fixing upper rear frame / M8x1.25 / 24.5-26.5 / 2.5-2.7 / 18.1-19.5
Nut fixing lower rear frame / M8x1.25 / 24.5-26.5 / 2.5-2.7 / 18.1-19.5
Nut fixing chain roller / M8x1.25 / 25.5-28.5 / 2.6-2.9 / / 18.8-21
Nut fixing engine front / M8x1.25 / 33.3-37.3 / 3.4-3.8 / 24.5-27.5
Nut fixing engine low side / M8x1.25 / 33.3-37.3 / 3.4-3.8 / 24.5-27.5
Screw for rotation of side stand (WR) / M8x1.25 (***) / 11.7-11.9 / 1.19-1.21 / 8.60-8.75
Screw for fixing the plate for upper connection to the frame / M8x1.25 / 24.5-26.5 / 2.5-2.7 / 18.1-19.5
Screw fixing engine upper side / M8x1.25 / 24.5-26.5 / 2.5-2.7 / 18.1-19.5
Screw fixing front brake connection / M6x1 / 4.7-5.1 / 0.48-0.52 / 3.5-3.8
Screw for fixing the front brake pipes on brake pump / M10x1 / 23.5-25.5 / 2.4-2.6 / 17.3-18.8
Screw fixing clutch connection / M6x1 / 4.7-5.1 / 0.48-0.52 / 3.5-3.8
Screw fixing rear brake pedal / M10x1.25 (*) / 39-44 / 4.0-4.5 / 29-32.5
Screw fixing rear brake pump / M6x1 / 9.8-10.8 / 1.0-1.1 / / 7.2-8.0
Screw fixing brake fluid tank / M6x1 / 2.35-2.55 / 0.24-0.26 / 1.73-1.88
Screw fixing rear brake pipe / M10x1 / 18.1-20.1 / 1.85-2.05 / 13.4-14.8
Rear light switch (WR) / M10x1 / 13.8-15.7 / 1.4-1.6 10. / 1-11.6
Screw fixing front wheel axle / M10x1.5 / 49-55 / 5.0-5.5 / 36.2-39.8
Screw fixing fork rods / M8x1.25 / / 23.5-25.5 / 2.4-2.6 / 17.3-18.8
Ring nut for handlebar bearing adjustment (1st turn) / M25x1 / 3.2-3.6 / 0.33-0.37 / 2.4-2.7
Nut for handlebar pin / M24x1 / 79-87 / 8.1-8.9 / 58-64
Screw for fixing the brake pedal adjusting cam / M6x1 / 18.1-20.1 / 1.85-2.05 / 13.4-14.8

(*) LOCTITE 243
(**) LOCTITE 270
(***) LOCTITE 242

I also found this:

NOTE - If not otherwise specified, standard tightening torques for the following thread:
M5x0.8 / 4.9-6.9 / 0.5-0.7 / 3.6-5
M6x1 / 8.8-9.8 / 0.9-1 / 6.5-7.2
M8x1.25 / 21.6-23.3 / 2.2-2.4 / 16-17.3

While I appreciate the effort, What Gives??

How can there not be a full service manual that comes with the bike?
Or that is at least available to buy?

It almost becomes a safety issue to not have the correct specs/torque.

I'm trying to race prep a bike to put my son on and it does not make me all warm and fuzzy to be guessing at the setup torques. :shocked:

Do you think the one for the '08 would be acceptable, at least for torque specs?

Has anybody had any luck through the dealers or directly with Husky?

Just used these for putting my 144 kit on. Thanks for the assist Wally and Mike!

this is my biggest gripe about the husky. my ktm and kawasaki manuals were far superiour as far as detail and ease of desifering.

what bolts and nuts are you looking for in particular? if you tell us id be happy to look in my 06 manual and let you know what i find.