🏷️ Basic Information

Make:

Husqvarna

Model:

SM 125 S

Model Variant:

Supermoto

Product Type:

Service Repair Manual

Model Generation:

Likely representing the early 2000s generation of the SM 125 S platform.

Chassis Code Identifier:

Not explicitly provided, but typically denoted by an 'A' series for this era (e.g., CR 125 A).

👋 Introduction

Motorcycle Segment:

Lightweight Supermoto / Motard

Target Audience:

Enthusiasts and riders seeking agile on-road performance with a dirt bike feel.

Key Competitors:

Yamaha WR125X, Aprilia SX 125, Beta RR 125 Motard, CCM R30. Competes in the popular 125cc segment for younger riders or those seeking an economical, nimble urban or track-day machine.

Performance Focus:

Designed for agility, quick handling, and spirited riding on paved surfaces.

Design Philosophy:

Combines a capable dirt bike chassis with road-biased tires and suspension for a versatile supermoto experience.

Manual Value Proposition:

Provides comprehensive, authoritative guidance for maintaining and repairing the SM 125 S, ensuring longevity and optimal performance.

📋 Manual Details

Model Years Covered:

2000, 2001, 2002, 2003

Regional Applicability:

Primarily European markets, with potential applicability to other global markets depending on specification.

Estimated Page Count:

Hundreds of pages (specific count not provided, but typical for comprehensive service manuals).

Manual Classification:

Service and Repair Manual

Intended User:

Professional Technicians and DIY Mechanics

Language Of Publication:

Likely English, with potential for other European languages depending on the original manufacturer's distribution.

Digital Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, including disassembly, inspection, assembly, and torque specifications for all internal components.

Fuel System:

Carburetor tuning, rebuilding, fuel pump service (if applicable), fuel filter replacement, and fuel line inspection.

Ignition System:

Spark plug specifications, ignition timing, coil testing, stator and CDI unit troubleshooting.

Cooling System:

Radiator service, coolant type and capacity, water pump inspection and replacement, thermostat operation.

Exhaust System:

Exhaust pipe and silencer removal, inspection for damage, and reinstallation procedures.

Transmission:

Clutch inspection and adjustment, gearbox disassembly and reassembly, gear shift mechanism, and transmission oil specifications.

Chassis Frame:

Frame inspection for cracks or damage, steering head bearing service, and frame component torque values.

Suspension Front:

Front fork service, including oil type, level, seal replacement, spring replacement, and damping adjustment procedures.

Suspension Rear:

Rear shock absorber service, linkage inspection, bearing lubrication, and spring pre-load adjustment.

Brakes Front:

Brake caliper service, pad replacement, disc inspection, brake fluid type and bleeding procedures.

Brakes Rear:

Rear brake caliper service, pad replacement, disc inspection, brake fluid type and bleeding procedures.

Wheels And Tires:

Wheel bearing service, spoke tensioning (if applicable), tire pressure recommendations, and wheel removal/installation.

Electrical System:

Wiring diagrams, component testing (lights, horn, signals), battery maintenance, and fuse identification.

Bodywork And Plastics:

Fairing removal and installation, seat removal, and general body panel maintenance.

Maintenance:

Routine maintenance checks, lubrication points, filter replacement intervals, and seasonal storage procedures.

Troubleshooting:

Diagnostic charts for common running issues, electrical faults, and mechanical problems.

Repair:

Step-by-step instructions for component repair, rebuilding, and replacement.

Rebuilds:

Comprehensive instructions for engine and transmission rebuilds.

Refurbishment:

Guidance on restoring various components to original specifications.

Restoration:

Detailed procedures relevant to bringing the motorcycle back to its original condition.

Diagnostic Capabilities:

Advanced diagnostic procedures for identifying and rectifying complex issues across all systems.

Rebuild Instructions Detail:

Detailed, component-level rebuild instructions with critical tolerances and specifications.

Electrical Schematics:

Inclusion of comprehensive electrical wiring diagrams for accurate troubleshooting.

Torque Specifications:

Inclusion of all critical torque specifications for fasteners and internal components.

Special Tool Requirements:

Identification and description of any specialized tools required for specific procedures.

📊 Manual Specifications

Digital File Type:

PDF

Searchability:

Likely searchable text within the PDF for efficient information retrieval.

Printability:

Printable pages for hands-on use in a workshop environment.

Image Resolution:

Expected to be high enough to clearly view diagrams and illustrations.

Physical Binding:

N/A (as it is a PDF)

Physical Paper Quality:

N/A (as it is a PDF)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, two-stroke, single-cylinder

Displacement:

124.8 cc (9.84 cu in)

Bore X Stroke:

54 mm x 54.5 mm (2.13 in x 2.15 in)

Compression Ratio:

Approx. 8.8:1 (variations may exist based on specific market tuning)

Power Output:

Approx. 15 HP (11.2 kW) at 8,000 rpm (typical for 125cc two-strokes in this era, subject to restrictions)

Torque:

Approx. 12 Nm (8.9 lb-ft) at 7,500 rpm (estimated)

Top Speed:

Subject to rider weight, conditions, and local regulations; typically around 100-110 km/h (62-68 mph).

Carburetor:

Dell'Orto PHBH 28 DD (or similar specification)

Fuel Type:

Unleaded gasoline, minimum Octane rating of 95 (RON).

Fuel Tank Capacity:

Approximately 9.5 liters (2.5 US gallons)

Oil Mixture:

Pre-mix or separate oil injection system (depending on specific market variant and build date), typically a 2-stroke synthetic oil with a 50:1 or 40:1 ratio for pre-mix.

🔧 Transmission

Transmission Type:

6-speed constant mesh

Transmission Options:

N/A (typically a single standard transmission for this model)

Clutch Type:

Wet multi-plate clutch

Final Drive:

Chain drive (e.g., 520 O-ring chain)

Gear Ratios:

Specific ratios would be detailed within the manual, crucial for performance tuning.

Transmission Oil:

SAE 10W/40 or 20W/40 API GL-3 or GL-4 transmission oil. Capacity typically around 0.8-1.0 liters.

📐 Dimensions

Length:

Approximately 2050 mm (80.7 in)

Width:

Approximately 760 mm (29.9 in)

Height:

Approximately 1170 mm (46.1 in)

Wheelbase:

Approximately 1430 mm (56.3 in)

Seat Height:

Approximately 860 mm (33.9 in)

Ground Clearance:

Approximately 280 mm (11.0 in)

Cargo Capacity:

N/A (motorcycle, no dedicated cargo space)

Dry Weight:

Approximately 105-110 kg (231-243 lbs)

Wet Weight:

Approximately 118-123 kg (260-271 lbs) (with fluids)

🛡️ Safety Features

Safety Ratings:

Motorcycle safety is assessed by regulatory bodies and rider experience, not standardized crash ratings like cars.

Braking System:

Hydraulic disc brakes front and rear for effective stopping power. Front typically a larger diameter disc (e.g., 300mm) with a dual-piston caliper.

Lighting:

Headlight, taillight, brake light, and turn signals for visibility and signaling.

Chassis Design:

Rigid frame and capable suspension contribute to stable handling and rider control.

Tire Selection:

Supermoto-style tires offer good grip on paved surfaces. Manual will specify recommended tire pressures and types.

💡 Technology Features

Instrument Cluster:

Analog speedometer and tachometer, with indicator lights for turn signals, high beam, oil level (if applicable), and neutral.

ABS:

N/A (ABS was not a common feature on lightweight 125cc motorcycles of this era).

Connectivity Features:

N/A (basic motorcycle electronics).

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually. For two-stroke, oil injection system checks are critical.

Spark Plug Replacement:

Recommended every 5,000 - 7,500 km (3,000 - 4,500 miles), depending on plug type and usage.

Air Filter Cleaning Replacement:

Frequent checks recommended, especially if ridden in dusty conditions. Clean every 1,000-2,000 km, replace as needed.

Chain Lubrication Adjustment:

Lubricate every 500 km (300 miles) and check/adjust tension every 1,000 km (600 miles).

Top End Rebuild Recommendation:

For two-strokes, piston and ring inspection/replacement typically recommended around 10,000 - 15,000 km (6,000 - 9,000 miles) depending on riding style.

Engine Oil:

For two-stroke pre-mix: High-quality synthetic 2T engine oil meeting JASO FD or ISO-L-EGD standards. For separate oil injection: Specific 2T injector oil recommended by Husqvarna.

Transmission Oil:

SAE 10W/40 or 20W/40 API GL-3 or GL-4.

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors. Mixture ratio typically 50:50 with distilled water. Capacity approx. 1.5 liters.

Brake Fluid:

DOT 4 brake fluid.

Common Wear Items:

Clutch plates, piston rings, brake pads, chain and sprockets, wheel bearings, and exhaust packing (if equipped).

Carburetor Tuning Sensitivity:

Two-stroke carburetors can be sensitive to altitude, temperature, and fuel quality. The manual will provide baseline settings.

Cooling System Maintenance:

Regular flushing and coolant checks are important to prevent overheating, especially during spirited riding.

📚 Vehicle History

Husqvarna Motorcycles Legacy:

Husqvarna is one of the oldest motorcycle manufacturers, with a rich history in off-road and racing disciplines. Known for its Swedish engineering and robust designs.

Sm 125 Series Development:

The SM 125 S represents Husqvarna's entry into the popular 125cc supermoto segment, leveraging their experience from motocross and enduro bikes. This model aimed to provide an accessible yet performance-oriented supermoto machine.

Manufacturing Location:

Primarily produced in Italy during this period, under ownership that included Cagiva Group.

Production Era:

Early 2000s, a period where lightweight supermotos gained significant popularity in Europe.

🏆 Awards & Recognition

Motorcycle Awards:

Specific awards for the 2000-2003 SM 125 S are not widely documented. However, the model was generally well-regarded in its class for its performance and handling.