Vehicle Segment:
Off-road motorcycle, Enduro/Motocross (2-stroke).
Target Audience:
Enthusiast riders and mechanics focused on maintaining and repairing their Husqvarna WR250/CR250.
Key Competitors Era:
KTM EXC/SX 250, Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250.
Engine Configuration:
2-stroke, single-cylinder liquid-cooled.
Performance Focus:
Agile handling, strong power delivery characteristic of 2-stroke off-road bikes.
Manual Value Proposition:
Provides detailed, manufacturer-level technical data essential for accurate and efficient repairs and maintenance.
Engine Mechanical:
Complete engine teardown, assembly, component specifications, torque values, timing, lubrication.
Engine Electrical:
Ignition system, stator, CDI unit, wiring diagrams, troubleshooting electrical faults.
Fuel System:
Carburetor (type, jetting, adjustment), fuel lines, fuel tank.
Cooling System:
Radiator, hoses, coolant specifications, water pump.
Exhaust System:
Exhaust pipe, silencer, packing, mounting.
Transmission:
Clutch (operation, adjustment, replacement), gearbox (disassembly, assembly, lubrication, gear selection).
Drivetrain:
Chain adjustment, sprockets, general drivetrain maintenance.
Suspension:
Front forks (disassembly, oil levels, seals, spring rates), rear shock absorber (rebuild, adjustments), linkage system.
Brakes:
Front and rear brake systems (hydraulic lines, master cylinders, calipers, pads, rotors, bleeding procedures).
Wheels And Tires:
Spoke maintenance, bearing replacement, tire selection and mounting.
Frame And Bodywork:
Frame inspection, plastic panel removal and installation, seat, handlebars, footpegs.
Controls:
Throttle, clutch lever, brake lever adjustments and cable replacement.
Routine Maintenance:
Oil changes, filter cleaning/replacement, chain lubrication, spark plug inspection.
Troubleshooting:
Diagnostic procedures for common issues, fault finding charts.
Component Rebuild:
Full overhaul instructions for engine, transmission, suspension, and brake components.
Adjustments:
Carburetor tuning, clutch and throttle cable adjustments, suspension sag.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Depth Level:
Comprehensive (suitable for professional mechanics and experienced DIY enthusiasts).
Detail Level:
Includes torque specifications, clearances, tolerances, part numbers (where applicable in original manual), and step-by-step repair procedures.
Engine Type:
2-stroke, single-cylinder, reed valve induction.
Displacement:
Approximately 249cc (specific bore/stroke likely detailed in manual).
Bore X Stroke:
Likely around 66.4 mm x 72 mm (verify with manual for exact specs).
Cooling System:
Liquid-cooled.
Compression Ratio:
Typically in the range of 8.0:1 to 9.5:1 for this era (refer to manual).
Ignition System:
Digital CDI (Capacitor Discharge Ignition).
Horsepower:
Estimated 40-45 HP at peak RPM (refer to manual for exact dyno figures).
Torque:
Estimated 25-28 lb-ft at peak torque (refer to manual for exact figures).
Carburetor Type:
Likely Mikuni TMX series (e.g., TM38-85) or Keihin PWK (verify with manual).
Fuel Type:
Unleaded gasoline, typically 90 octane or higher.
2-Stroke Oil Mixing:
Premix or Autolube system (manual will specify, likely premix for racing variants).
Transmission Type:
6-speed constant mesh.
Clutch Type:
Wet, multi-plate, cable-actuated.
Optional Gearing:
Aftermarket sprockets and gear sets could be installed.
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Transmission Fluid Type:
Likely a specific 2-stroke transmission oil (e.g., SAE 80W/90 or dedicated gear oil, confirm with manual).
Clutch Adjustment:
Manual will detail free play adjustment for optimal clutch engagement.
Wheelbase:
Approximately 57-58 inches (refer to manual for exact measurement).
Seat Height:
Approximately 37-38 inches (unladen, refer to manual).
Ground Clearance:
Typically around 13-14 inches (refer to manual).
Dry Weight:
Approximately 220-230 lbs (without fluids, refer to manual).
Wet Weight:
Approximately 240-250 lbs (with all fluids, estimate).
Oil Change Interval:
Engine oil: Every 10-15 hours of riding or annually. Transmission oil: Every 20-30 hours of riding or annually (refer to manual for precise intervals).
Air Filter Cleaning:
Clean after every few rides, or more frequently in dusty conditions.
Spark Plug Inspection:
Inspect every 15-20 hours of riding.
Piston Ring Replacement:
Recommended every 40-60 hours of riding for optimal performance.
Top End Rebuild:
Recommended every 80-100 hours of riding (piston, rings, cylinder inspection).
Engine Oil Type:
High-quality 2-stroke synthetic oil meeting JASO FD or ISO-L-EGD standards (specific recommendations in manual).
Transmission Oil Spec:
Specific 2-stroke motorcycle transmission oil (e.g., SAE 80W/90 gear oil or a dedicated wet-clutch compatible oil - consult manual).
Coolant Type:
Ethylene glycol-based coolant, mixed with distilled water (50/50 ratio typical, confirm in manual).
Fork Oil Type:
Specific suspension fork oil (viscosity like SAE 5W or 10W is common, manual will specify exact type and volume).
Carburetor Fouling:
Common with 2-strokes; requires regular cleaning and proper jetting for conditions.
Clutch Wear:
Clutch plates can wear, requiring adjustment or replacement, especially with aggressive riding.
Suspension Seal Leaks:
Fork seals can weep or fail, requiring replacement and fork oil service.
Power Valve Sticking:
Carbon buildup can cause the power valve to stick, affecting engine performance; requires periodic cleaning.
Brand Origin:
Husqvarna motorcycles have a long and storied history originating from Sweden, dating back to 1903. Known for pioneering off-road and motocross technology.
2-Stroke Development:
The WR250/CR250 lineage represents Husqvarna's strong presence in the competitive 2-stroke off-road market. These models evolved with advancements in chassis design, engine performance, and suspension technology.
2004-2005 Era:
This period saw significant competition, with manufacturers constantly refining their 250cc 2-stroke offerings. Husqvarna aimed to deliver competitive performance and durability.
Manufacturing Location:
Likely manufactured in Sweden or potentially Italy during this period, depending on corporate ownership at the time (Husqvarna was part of BMW ownership for a period leading up to this, though production could have still been in older facilities).
