2008 Husqvarna CR 125 / WR 125 Workshop Manual (P/N 8000 B0503)

This 418-page PDF is the first-edition factory workshop manual for the 2008 Husqvarna CR 125 motocross bike and WR 125 enduro, issued June 2007 as P/N 8000 B0503. Its 18 sections cover the complete motorcycle, not just the 125cc two-stroke powertrain, and present the material in English, Italian, French, German, and Spanish. The internal repair depth and reliance on factory pullers, holding tools, and precision measurement make it best suited to experienced two-stroke mechanics and well-equipped owners rather than first-time rebuilders.

• Model coverage: Valid from VIN ZCG2H00AA8V050001 for CR 125, ZCG2H00AA8V000011 for WR 125, ZCGCR123*8V000001 for CR 125 USA/CDN, and ZCGWR123*8V000001 for WR 125 USA/CDN.
• Engine repair: Covers engine removal, staged teardown, crankcase splitting, cylinder and piston inspection, connecting-rod and crankshaft checks, bearing and seal replacement, reed-valve service, Mikuni TMX 38 carburetor overhaul, and complete reassembly.
• Clutch and transmission: Details clutch-disc replacement, basket and hub inspection, primary-drive checks, selector-fork and shift-shaft inspection, six-speed constant-mesh gearbox service, and drive-sprocket removal and installation.
• Chassis and suspension: Includes Marzocchi upside-down fork removal, adjustment, and internal service; steering and swingarm bearings; rear linkage; wheel and hub overhaul; and Sachs rear shock removal. Full shock disassembly, overhaul, and reassembly is specifically identified for the WR 125.
• Brakes, cooling, and setup: Provides caliper and master-cylinder coverage, pad and disc inspection, front and rear brake bleeding, fluid replacement, cooling-circuit overhaul, chain wear and alignment checks, and suspension sag, spring-preload, and damping adjustments.
• Electrical diagnosis: Supplies separate CR and WR ignition layouts, WR alternator and voltage-regulator tests, CR digital power-unit coverage, ignition-timing procedures, WR instrument setup, wiring legends, cable-color identification, and regional lighting information.
• Competition versus street configuration: Separates hour-based maintenance schedules for CR and full-power WR competition use from kilometer-based schedules for the standard limited-power WR street configuration, with a dedicated WR racing-conversion section for the carburetor kit and exhaust.

Factory Repair Data

The overhaul sections include component clearances, wear limits, shaft runout checks, carburetor settings, ignition data, suspension setup information, approved fluids and capacities, and component-specific torque tables in Nm, kgm, and lb-ft. These tables are tied to the illustrated disassembly and assembly sequences, including cross-pattern cylinder and head installation.

Tool requirements are unusually well documented. The manual lists different flywheel extractors for the WR (8000 60516) and CR (8000 46613), model-specific ignition-control tools (8000 86950 and 8000 79831), a clutch-hub retaining wrench (8000 79015), and the crankcase-splitting/crankshaft removal tool (8000 79016). Those callouts help establish what equipment is needed before an internal repair begins.

CR, WR, and Regional Differences

The CR is treated as a full-power competition motorcycle, while the standard WR is documented in limited-power street configuration. The WR racing-use chapter identifies carburetor kit P/N 8000 A5971 and racing exhaust pipe P/N 8000 A8424; the optional-parts section also lists USA/CDN Enduro kit P/N 8000 B0539. The electrical systems differ as well: the WR uses analog ignition with voltage-regulated lighting equipment, while the CR uses a digital ignition unit.

Reference graphics include the WR wiring diagram and cable-color key, the “WR 125 Enduro USA” wiring diagram, separate WR and CR electronic-ignition schematics, the ignition timing curve, and the H.T.S. (Husqvarna Torque System) exhaust-valve linkage and position view. Exploded views support the clutch, primary drive, gearbox, fork, shock, and engine assembly sections.

Repair Cautions and Scope

The H.T.S. system uses a mechanically governed twin exhaust valve whose installed position is checked against piston clearance; incorrect indexing can allow valve-to-piston contact. The ignition coil also depends on a clean frame ground. Paint or corrosion at the mounting point can damage the coil and cause starting faults.

Brake bleeding and pressurized shock work require proper workshop equipment. Follow the manual's bleeding, charging, leak-check, and final operational checks before returning the motorcycle to service.

The Troubles and Remedies section is a short cause-and-remedy chart for spark-plug fouling or overheating and WR charging faults, not a system-wide diagnostic guide. Parts coverage is limited to an optional-parts list; the separate parts catalog referenced in the manual is not included in this PDF.