2005 Husqvarna WR 250 Workshop Service Repair Manual Download 05 PDF

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Type: Motorcycle

Vendor:

Sku: 54824

Tags: 2005 Husqvarna Misc Motorcycle Motorcycles WR 250

Product variants

Description

The 2005 WR 250 is a performance-oriented 2-stroke enduro motorcycle, celebrated for its potent power delivery and agile handling, designed for off-road competition and recreational riding. As a model from a brand with a rich heritage dating back to 1903, the WR 250 embodies decades of evolution in enduro technology, offering a compelling package that often received positive reviews for its strong engine and capability. This model, primarily manufactured in Italy, stands as a testament to dedication to off-road prowess, making it a favored choice for riders seeking a competitive edge on challenging terrain. This comprehensive workshop service repair manual provides detailed guidance for maintaining and repairing the 2005 WR 250. Covering over 500 pages of information in English, it offers in-depth procedures for engine disassembly and repair, fuel and ignition systems, transmission, suspension, brakes, and electrical systems. It also includes preventative maintenance schedules, troubleshooting guides, and specific instructions for special tools. This manual is an essential resource for owners, mechanics, and technicians aiming to ensure the optimal performance and longevity of their WR 250.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

WR 250

Year:

Codes

Product Identifier:

2005 Husqvarna WR 250 Workshop Service Repair Manual Download 05 PDF

👋 Introduction

Market Position

Market Segment:

Off-road/Enduro competition and recreational riding.

Competitive Analysis

Competitors 2005:

KTM 250 EXC, Yamaha YZ250 (WR variant), Honda CR250R (off-road variant), Suzuki RM250 (off-road variant), Kawasaki KX250 (off-road variant).

Key Features

Model Focus:

Performance-oriented 2-stroke enduro motorcycle known for its power delivery and handling.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service Repair

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Repair Manual (OEM)

Language

Language:

English

Format

Format:

Downloadable PDF

Manual Specifications

File Format Quality:

High-resolution PDF with searchable text and clear image rendering.

Print Quality:

Printable pages with clear text and diagrams suitable for professional use.

Binding Type:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and reassembly for the 2-stroke 250cc engine.

Fuel System:

Carburetor tuning, cleaning, and overhaul; fuel tank and petcock maintenance.

Cooling System:

Radiator, hoses, thermostat, and coolant replacement procedures.

Ignition System:

Spark plug specifications, ignition coil testing, CDI unit diagnostics.

Exhaust System:

Pipe and silencer maintenance, inspection for damage and leaks.

Transmission:

Gearbox disassembly, inspection, clutch operation, and lubrication.

Drivetrain:

Chain and sprocket inspection, adjustment, and replacement; rear hub maintenance.

Suspension Front:

Fork seal replacement, oil changes, spring preload adjustment, damper settings.

Suspension Rear:

Monoshock absorber servicing, linkage maintenance, spring replacement, adjustments.

Brakes Front:

Caliper overhaul, pad replacement, fluid bleeding, disc inspection.

Brakes Rear:

Caliper overhaul, pad replacement, fluid bleeding, disc inspection.

Wheels Tires:

Spoke tensioning, rim inspection, tire mounting and balancing, wheel bearing service.

Electrical System:

Wiring diagrams, lighting system diagnostics, battery maintenance, switchgear.

Frame Chassis:

Frame inspection, swingarm pivot service, steering head bearing replacement.

Bodywork:

Plastic panel removal and installation, seat maintenance, fender replacement.

Procedures Included

Preventative Maintenance:

Regular service intervals, lubrication points, filter changes.

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues.

Repair Procedures:

Step-by-step instructions for all major component repairs and overhauls.

Disassembly Reassembly:

Detailed guides for stripping down and rebuilding all vehicle systems.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive (OEM level) covering basic maintenance to complete engine and chassis rebuilds.

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, liquid-cooled, reed-valve inducted

Displacement:

249.1 cc

Bore X Stroke:

66.4 mm x 72 mm

Compression Ratio:

8.7:1 (Nominal)

Power Output Estimated:

Approx. 35-40 HP (at crank, depending on tuning)

Torque Output Estimated:

Approx. 25-30 lb-ft (at crank)

Performance

Carburetor Model:

Keihin PWK 38 (typically)

Fuel System

Fuel Type:

Unleaded gasoline (91+ octane recommended) mixed with 2-stroke oil

Oil Mixture Ratio:

50:1 (Standard, refer to manual for specific oil type)

Fuel Tank Capacity:

Approx. 2.5 gallons (9.5 liters)

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Optional

Clutch Type:

Wet, multi-plate, cable-actuated

Features

Gear Ratios:

Specific gear ratios are detailed within the manual, crucial for performance tuning.

Transmission Oil Type:

Refer to manual; typically a high-quality 10W/40 or 80W/90 gear oil or specific transmission fluid.

Transmission Oil Capacity:

Approx. 0.8 - 1.0 liters (refer to manual for precise capacity).

📐 Dimensions

Exterior

Length:

Approx. 2170 mm (85.4 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1220 mm (48 in)

Wheelbase:

Approx. 1475 mm (58.1 in)

Ground Clearance:

Approx. 350 mm (13.8 in)

Weights

Dry Weight:

Approx. 105 kg (231.5 lbs)

Curb Weight:

Approx. 115 kg (253.5 lbs) (estimated with fluids)

Max Load Capacity:

Refer to manual; typically for rider and minimal gear.

🛡️ Safety Features

Ratings

Crash Safety:

Not applicable for off-road motorcycles in the same way as road vehicles; focus is on rider protection.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Chassis Design:

Designed for agile handling and stability in off-road conditions.

Passive Features

Handguards:

Standard or optional handguards to protect hands from debris and levers.

💡 Technology Features

Infotainment

Features:

None (focus is on performance and off-road capability, not consumer electronics).

Driver Assistance

Features:

None (designed for rider control and experience).

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 20-30 hours of riding, or as specified in the manual.

Air Filter Cleaning:

After every few rides or in dusty conditions; detailed cleaning procedure in manual.

Spark Plug Replacement:

Every 50-100 hours of riding, depending on usage and plug type.

Top End Rebuild:

Intervals vary greatly based on usage and maintenance, typically 100-200 hours for piston/rings. Manual provides wear limits.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., 50/50 mix with distilled water).

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Specific viscosity (e.g., 5W or 7.5W) and level, detailed in manual.

Known Issues

Common Wear Items:

Clutch plates, piston rings, fork seals, wheel bearings, chain, and sprockets are typical wear items.

Carburetor Tuning:

Can be sensitive to altitude and temperature changes; requires diligent tuning.

Cooling System Maintenance:

Regular flushing and proper coolant levels are critical for the 2-stroke engine's longevity.

2 Stroke Specifics:

Requires meticulous attention to fuel/oil mixture and regular decarbonization of the exhaust port.

📚 Vehicle History

Brand Heritage

Brand Origin:

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

Model Evolution

Wr Series:

The WR series has a long lineage in enduro and cross-country racing, evolving over decades to incorporate technological advancements.

Production

Manufacturing Location:

Primarily Italy during this period, under ownership by MV Agusta and later BMW.

Model Run:

The WR 250 has been a staple in Husqvarna's lineup for many years, with continuous updates.

🏆 Awards & Recognition

Recognitions

Media Reviews:

The WR 250 generally received positive reviews for its strong engine, agile handling, and competitive pricing in its class during its production years.

Ratings

Owner Satisfaction:

High for owners who appreciate its potent 2-stroke performance and off-road prowess, provided regular maintenance is performed.