2012 Husqvarna CR 65 Service & Repair Manual (1st Edition)

• Coverage and document identity: Official Husqvarna 2012 CR 65 workshop publication for motorcycles from chassis serial number ZKHCR6530CV000001 onward; 1st Edition (09-2011), 174-page PDF.
• Engine repair: Covers engine removal, top-end disassembly, piston and cylinder inspection, water-pump service, crankcase splitting, crankshaft removal and installation, reed-valve inspection, and engine reassembly.
• Transmission and clutch: Details the constant-mesh six-speed gearbox, input and output shaft inspection and assembly, selector drum and shift-fork service, clutch-pack inspection, kick-start mechanism setup, and hydraulic clutch work.
• Fuel and ignition: Includes Mikuni TM24 carburetor removal, disassembly, wear checks, float and jet inspection, seasonal setup data, fixed spark-advance adjustment, ignition resistance tests, and peak-voltage fault checks.
• Chassis and running gear: Provides fork removal and adjustment, rear shock setup, swingarm and suspension-linkage service, steering-bearing adjustment, wheel service, axle and rim checks, chain alignment, and sprocket inspection.
• Brake, cooling, and hydraulic procedures: Covers pad and disc inspection, front and rear brake bleeding, brake-fluid replacement, clutch master-cylinder service and circuit filling, radiator and hose inspection, and water-pump repair.
• Workshop reference: Includes race-use maintenance schedules, engine/chassis/electrical troubleshooting tables, tightening-torque charts, capacities, approved lubricants, wear limits, clearances, electrical test values, special tools, and labeled system drawings.

Husqvarna states that this workshop manual was designed for its Service Centers and authorized personnel. Its repair depth is therefore best suited to trained technicians and experienced mechanics who have the specified pullers, measuring equipment, electrical meters, press and heating equipment, and secure motorcycle and engine stands available.

Engine and Drivetrain Depth

The engine chapters map the job from removal through teardown, inspection, and final reassembly. They cover the cylinder head, cylinder and piston, reed valve, clutch, primary drive, kick-start system, ignition rotor and stator, crankshaft, crankcase bearings and seals, water pump, and gearbox controls. Separate overhaul data addresses crankshaft alignment and big-end clearance, piston-ring and piston-to-cylinder limits, matched piston/cylinder size classes, clutch wear, and gearbox shaft clearances.

Transmission coverage shows how the input and output shafts are stripped, inspected, and built, including gear orientation, circlip direction, thrust washers, selector forks, guiding rods, and selector-drum shimming. Factory reassembly coverage continues through crankcase joining, clutch installation, kick-start preload, primary-drive installation, water-pump engagement, fixed spark-advance setting, cylinder-head installation, and gearbox filling.

Fuel, Ignition, and Troubleshooting

The fuel chapter explains the Mikuni TM24 circuits at idle, throttle opening, partial load, and full load. It also covers carburetor removal and repair, the cold-start device, throttle valve and taper needle, float needle, jets, seals, float level, and the factory summer/winter setup. The troubleshooting tables connect hard starting, noise, power loss, overheating, clutch slip, shifting faults, chassis vibration, suspension behavior, weak braking, and spark-plug symptoms with likely causes and repair directions.

Electrical coverage is specific to the racing ignition system. It supplies the ignition/engine-stop wiring diagram, component locations, stator and ignition-coil resistance checks, and static output testing with a peak-voltage adapter. It is not a road-model lighting or charging-system manual.

Chassis Systems and Scope Limits

The chassis sections cover brake-pad replacement, front and rear brake bleeding, hydraulic-clutch draining and filling, master-cylinder service, cooling-circuit checks, wheel-bearing replacement, wheel alignment, spoke and rim inspection, and swingarm/linkage bearing service. Suspension setup includes fork position, separate compression and rebound adjustments, rear spring preload, rider sag, and shock damping.

Front suspension coverage stops at fork removal, spring and oil data, external adjustment, and dust-seal service; it does not include an internal fork-cartridge rebuild. Rear coverage documents shock removal and adjustment plus the linkage and swingarm, but not an internal shock rebuild.

Diagrams, Special Tools, and Repair Cautions

Illustrated references include the ignition wiring diagram, cooling-circuit schematic, hydraulic-clutch exploded view, carburetor drawing, and front/rear braking-system layout. The special-tool list identifies Husqvarna crankshaft remover 8000 H7677, primary-gear retainer 8000 H7678, spark-advance gauge 8000 H7679, and flywheel puller 8000 46613, along with the required commercial pullers and clamp pliers.

The manual warns against locking the primary drive with a sector gear when loosening the sprocket nut because the crankshaft can be damaged. It also prohibits separating the crankcase halves with a screwdriver or similar tool because the sealing surfaces can be gouged. For wheel, suspension, or chassis repair, support the motorcycle securely on a stand, and never open the radiator cap while the cooling system is hot.