HUSQVARNA WR250 CR250 Digital Workshop Repair Manual 2004-2005

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🏷️ Basic Information Identification Make: Husqvarna Model: CR250 Year: 2004-2005 👋 Introduction Market Position Segment: Off-road/Motocross/Enduro Motorcycles Target Audience: Husqvarna WR250/CR250 owners, mechanics, enthusiasts seeking detailed repair and maintenance information...

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Type: Motorcycle

Vendor:

Sku: 29797

Tags: 2004 2005 CR250 Husqvarna Misc Motorcycle Motorcycles WR250

Product variants

Description

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

CR250

Year:

2004-2005

👋 Introduction

Market Position

Segment:

Off-road/Motocross/Enduro Motorcycles

Target Audience:

Husqvarna WR250/CR250 owners, mechanics, enthusiasts seeking detailed repair and maintenance information

Competitive Analysis

Competitors:

KTM EXC/SX, Yamaha YZ, Suzuki RM, Honda CR, Kawasaki KX

Key Features

Manual Value:

Essential resource for maintaining peak performance and longevity of Husqvarna WR250/CR250 models.

Accuracy:

Provides factory-level repair and diagnostic procedures for the specified model years.

Completeness:

Covers all major mechanical and electrical systems.

📋 Manual Details

Coverage Areas

Engine Coverage:

Complete engine overhaul, diagnostics, tuning, component replacement

Transmission Coverage:

Gearbox inspection, repair, clutch service, linkage adjustments

Chassis Coverage:

Frame inspection, suspension servicing (forks, rear shock), steering head bearing maintenance

Electrical Coverage:

Wiring diagrams, ignition system troubleshooting, lighting, charging system

Brake Coverage:

Hydraulic brake system service, caliper rebuilds, pad replacement, fluid bleeding

Bodywork Coverage:

Panel removal and installation, seat servicing, fuel tank maintenance

Cooling System Coverage:

Radiator service, coolant replacement, hose inspection

Fuel System Coverage:

Carburetor tuning and rebuilding, fuel line inspection, petcock service

Wheels Tires Coverage:

Tire changing, spoke tensioning, wheel bearing maintenance

Page Count

Estimated Pages:

N/A (Digital PDF, content-rich)

Manual Type

Type:

Digital Workshop Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (liquid-cooled variants), intake and exhaust systems

Transmission Systems:

Gear selection mechanism, shift drum and forks, clutch assembly (wet multi-plate), primary drive, gearbox lubrication

Electrical Systems:

Ignition system (CDI, spark plug), lighting (headlight, taillight, brake light), charging system (stator, rectifier/regulator), battery maintenance, starter motor (if applicable), wiring harness diagrams

Fuel And Carburetion Systems:

Carburetor model (e.g., Mikuni VM), jetting specifications, float bowl adjustment, idle speed settings, fuel delivery (petcock, fuel lines), air filter servicing

Suspension Systems:

Front telescopic forks (type, travel, oil type, oil level, seal replacement), rear monoshock suspension (shock absorber service, linkage bearings, spring preload adjustment)

Braking Systems:

Front and rear disc brakes, hydraulic system components (master cylinder, brake lines, calipers, brake pads), brake fluid type and bleeding procedures

Frame And Bodywork:

Frame inspection for cracks or damage, steering head bearings, body panel removal/installation, seat maintenance, fuel tank mounting and servicing

Wheels And Tires:

Spoke wheel maintenance, tire pressure specifications, tire removal and installation, wheel bearing service

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, valve clearance checks (if applicable)

Engine Rebuilding:

Complete engine teardown, piston and cylinder inspection/replacement, crankshaft and rod inspection, seal and gasket replacement, reassembly torque specifications

Carburetor Overhaul:

Disassembly, cleaning, jet replacement, float level adjustment, reassembly

Suspension Servicing:

Fork seal replacement, fork oil change, rear shock absorber maintenance, linkage bearing lubrication

Brake System Maintenance:

Brake pad replacement, brake caliper servicing, brake line inspection, brake fluid bleeding

Electrical Troubleshooting:

Diagnosis of ignition, lighting, and charging system faults using provided wiring diagrams

Clutch Replacement:

Clutch plate inspection and replacement, spring replacement, pressure plate adjustment

Diagnostic Procedures:

Step-by-step troubleshooting guides for common performance issues, starting problems, and component failures

Torque Specifications:

Critical torque values for all engine, chassis, and component fasteners

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, troubleshooting, component-level repair, and complete unit overhauls.

Detail Level:

Detailed step-by-step instructions with exploded views and diagrams

Diagnostic Tools Required:

Standard hand tools, specialized tools (e.g., piston ring compressor, flywheel puller), multimeter for electrical diagnostics

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (depending on PDF creation)

Printability:

Printable pages

Print Quality

Quality:

High-resolution digital images and clear text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled

Displacement:

249cc (approximate, specific to WR/CR variants)

Bore X Stroke:

Refer to manual for specific dimensions (typical for this era: ~66.4mm x 72mm)

Cylinder Layout:

Single cylinder

Valvetrain:

Reed valve intake, power valve exhaust

Ignition System:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower Output:

Refer to manual for specific dyno figures (typically 35-45 HP for this class/era)

Torque Output:

Refer to manual for specific figures

Fuel System

Carburetor Model:

Typically Mikuni VM series (e.g., VM38, VM39)

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (specific ratio in manual)

Fuel Tank Capacity:

Refer to manual (typically 7-10 liters)

Lubrication System

Type:

Premix or Autolube (depending on specific WR/CR variant and market, manual will clarify)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Features:

N/A (standard configuration for this model)

Features

Clutch Type:

Wet, multi-plate, cable-actuated

Gear Ratios:

Refer to manual for specific gear ratios

Final Drive:

Chain drive

Transmission Fluid:

Refer to manual for specification (typically SAE 80 or 10W-30 motorcycle specific)

📐 Dimensions

Exterior

Overall Length:

Refer to manual

Overall Width:

Refer to manual

Overall Height:

Refer to manual

Wheelbase:

Refer to manual (typical for this era: ~1470-1490 mm)

Ground Clearance:

Refer to manual

Weights

Dry Weight:

Refer to manual (typical for this era: ~100-110 kg)

Wet Weight:

Refer to manual

Gross Vehicle Weight Rating:

Refer to manual

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable to off-road motorcycles

Active Features

Braking System:

Hydraulic disc brakes (front and rear) for effective stopping power

Suspension Performance:

Provides stability and control over varied terrain

Passive Features

Handlebar Design:

Designed for rider control and feedback

Ergonomics:

Rider-centric design for optimal control and reduced fatigue

💡 Technology Features

Infotainment

Features:

N/A (Minimal electronic features typical of off-road motorcycles of this era)

Driver Assistance

Features:

Connectivity

Features:

Performance Enhancements

Power Valve System:

Variable exhaust port timing to optimize power delivery across the rev range.

Liquid Cooling:

Maintains optimal engine operating temperature for consistent performance and longevity.

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual (typically every 10-15 hours of use for engine oil)

Air Filter Cleaning:

Refer to manual (frequently, especially in dusty conditions, e.g., every 5-10 hours)

Chain Lubrication Adjustment:

Refer to manual (frequently, every ride or every few hours, check tension regularly)

Spark Plug Replacement:

Refer to manual (typically every 20-40 hours or as needed based on performance)

Top End Rebuild:

Refer to manual (typically every 40-80 hours for piston and rings, longer for cylinder)

Suspension Service:

Refer to manual (fork seals typically every 30-50 hours, full service annually or as needed)

Fluid Specifications

Engine Oil:

Refer to manual for specific viscosity and type (e.g., Motorex or equivalent 10W-40 4-stroke synthetic, if autolube is used)

Transmission Fluid:

Refer to manual for specific type and quantity (e.g., SAE 75W/90 or specific motorcycle gear oil)

Brake Fluid:

DOT 4 recommended (refer to manual for confirmation)

Coolant:

Ethylene glycol based coolant with corrosion inhibitors (refer to manual for specific type and mix ratio)

Known Issues

Carburetor Fouling:

Common with 2-strokes; requires regular cleaning and jetting checks.

Power Valve Sticking:

Can occur due to carbon buildup; requires periodic cleaning and lubrication.

Clutch Wear:

Clutch plates and springs can wear over time with hard use, requiring replacement.

Suspension Leaks:

Fork seals and rear shock seals are subject to wear and can develop leaks.

📚 Vehicle History

Brand Heritage

Brand Origin:

Husqvarna Motorcycles is one of the oldest motorcycle manufacturers in the world, founded in Sweden in 1903.

Motocross Legacy:

Husqvarna has a long and successful history in off-road racing, including motocross and enduro.

Model Evolution

Wr Cr Lineage:

The WR (Wide Ratio) and CR (Close Ratio) designations have been part of Husqvarna's off-road lineup for decades, evolving with technology and racing demands.

2004-2005 Era:

These models represent a period of continued development in 2-stroke technology and chassis design for Husqvarna.

Production

Manufacturing Location:

Typically Italy during this period, under BMW ownership (prior to KTM acquisition).

🏆 Awards & Recognition

Recognitions

Motocross Enduro Success:

Husqvarna has a strong competitive history in various off-road racing disciplines, with models from this era often performing well in their respective classes.

Ratings

Magazine Reviews:

Historically, Husqvarna off-road bikes have been praised for their handling, power delivery, and build quality, though specific awards for these exact model years would require searching archived literature.