2009-2010 Husqvarna WR 250 Workshop Service Repair Manual Download 09 10 PDF
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Basic Information Identification Make: Husqvarna Model: WR 250 Year: 2009-2010 Codes Manual Code: Likely internal product identifier, not explicitly stated in description. Introduction Market Position Market Segment: Off-road, Enduro motorcycle Target Audience: Husqvarna WR 250 owners, mechanics specializing in off-road motorcycles. Competitive Analysis Competitors Manuals: Comparable to official service manuals from KTM (which acquired Husqvarna), Yamaha, Honda, Suzuki in the same displacement class. Key Features Completeness: Described as 'Most Complete OEM', indicating comprehensive coverage. Diagnostic Focus: Emphasis on practical repair and troubleshooting for real-world conditions. Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English (assumed, standard for most OEM manuals) Format: PDF Download Page Count Page Count: Not specified, but typical for a comprehensive workshop manual covering multiple years and systems. Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, component specifications, torque values, timing. Fuel System: Carburetor tuning, fuel pump, fuel lines, fuel tank maintenance and repair. Ignition System: Ignition coil testing, spark plug specifications, CDI unit diagnostics. Cooling System: Radiator, hoses, coolant specifications, water pump repair. Exhaust System: Muffler, exhaust pipe maintenance, sealing. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, lubrication. Suspension: Front fork maintenance (oil change, seal replacement), rear shock absorber specifications and adjustment, linkage maintenance. Brakes: Hydraulic brake system service (master cylinder, calipers, lines), bleeding procedures, pad replacement, rotor specifications. Wheels Tires: Wheel bearing maintenance, spoke tensioning, tire pressure recommendations. Steering: Handlebar, triple clamp, steering stem bearing maintenance and adjustment. Electrical System: Wiring diagrams, lighting system, battery maintenance, charging system (stator/regulator), fuse specifications. Frame Chassis: Frame inspection, swingarm pivot maintenance, footpeg and control lever adjustment. Bodywork: Fairing removal and installation, seat, fuel tank removal and installation, fender maintenance. Procedures Included Routine Maintenance: Oil change intervals and specifications, air filter cleaning/replacement, spark plug gap and type, chain lubrication and adjustment. Troubleshooting: Diagnostic charts for common problems, symptom-based fault finding. Disassembly Assembly: Step-by-step instructions for major component removal and installation, including engine, gearbox, suspension, etc. Engine Rebuild: Piston replacement, ring gap adjustment, cylinder inspection and honing, crankshaft and connecting rod checks. Suspension Service: Front fork fluid replacement, seal head replacement, shock absorber rebuild (if applicable). Brake System Service: Bleeding procedures, caliper piston retraction, pad and rotor replacement. Electrical Diagnostics: Component testing using multimeters, wiring harness inspection, troubleshooting electrical faults. Carburetor Service: Jetting specifications, float level adjustment, cleaning and rebuilding. Technical Depth Depth Level: Comprehensive OEM level detail, suitable for professional mechanics and experienced DIY enthusiasts. Detail Scope: Includes precise torque specifications, clearances, tolerances, and diagnostic procedures. Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, enhancing ease of information retrieval. Print Quality Print Quality: Designed for clarity and legibility when printed, typically high-resolution. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Engine Specifications Primary Engine Engine Type: 2-Stroke Displacement: 249 cc (250cc class) Bore X Stroke: Specific dimensions available in manual, typically around 66.4 x 72 mm for this model. Cooling System: Liquid-cooled Intake: Reed valve induction, likely with a Mikuni carburetor. Performance Horsepower: Estimated 40-50 HP range, highly dependent on tuning and specific year variations. Torque: Peak torque figures typically in the 25-30 lb-ft range. Fuel System Carburetor Model: Likely Mikuni VM38 or similar size for the WR250. Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix (specified ratio in manual, e.g., 40:1 or 50:1). Transmission Standard Transmission Type: 6-speed constant mesh manual transmission Optional Optional Features: N/A (Standard configuration for this model). Features Clutch Type: Wet, multi-plate, hydraulically actuated clutch Gear Ratios: Specific ratios documented in the manual for each gear. Transmission Oil Spec: Manual will specify the correct grade and capacity for transmission lubrication (e.g., SAE 75W/80 or similar). Dimensions Exterior Wheelbase: Typically around 1470 mm (57.9 inches) for this generation. Seat Height: Around 950 mm (37.4 inches) unladen. Weights Dry Weight: Approximately 105-110 kg (231-242 lbs). Fuel Tank Capacity: Around 9-10 liters (2.4-2.6 US gallons). Safety Features Ratings Safety Ratings: N/A (Motorcycles are not typically rated by agencies like NHTSA for crashworthiness in the same way cars are). Active Features Braking System: Hydraulic disc brakes front and rear, with specific caliper and rotor sizes detailed in the manual. Suspension Travel: Significant suspension travel for off-road capability, front ~290-300mm, rear ~300-310mm. Passive Features Lighting: Headlight, taillight, brake light, turn signals (depending on market homologation). Technology Features Infotainment Infotainment System: N/A (Minimalist off-road motorcycle design). Driver Assistance Rider Aids: N/A (Focus on rider control and mechanical systems). Connectivity Connectivity Features: N/A Maintenance Service Intervals Engine Oil Change: Every 10-15 hours of riding or annually, specific grade documented in manual. Air Filter Cleaning: Recommended after every few rides or as needed based on conditions, detailed cleaning process in manual. Spark Plug Replacement: As per manual recommendations, typically based on hours or specific performance degradation. Chain Adjustment: Regularly, check for proper...
Frame inspection, swingarm pivot maintenance, footpeg and control lever adjustment.
Bodywork:
Fairing removal and installation, seat, fuel tank removal and installation, fender maintenance.
Procedures Included
Routine Maintenance:
Oil change intervals and specifications, air filter cleaning/replacement, spark plug gap and type, chain lubrication and adjustment.
Troubleshooting:
Diagnostic charts for common problems, symptom-based fault finding.
Disassembly Assembly:
Step-by-step instructions for major component removal and installation, including engine, gearbox, suspension, etc.
Engine Rebuild:
Piston replacement, ring gap adjustment, cylinder inspection and honing, crankshaft and connecting rod checks.
Suspension Service:
Front fork fluid replacement, seal head replacement, shock absorber rebuild (if applicable).
Brake System Service:
Bleeding procedures, caliper piston retraction, pad and rotor replacement.
Electrical Diagnostics:
Component testing using multimeters, wiring harness inspection, troubleshooting electrical faults.
Carburetor Service:
Jetting specifications, float level adjustment, cleaning and rebuilding.
Technical Depth
Depth Level:
Comprehensive OEM level detail, suitable for professional mechanics and experienced DIY enthusiasts.
Detail Scope:
Includes precise torque specifications, clearances, tolerances, and diagnostic procedures.
Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, enhancing ease of information retrieval.
Print Quality
Print Quality:
Designed for clarity and legibility when printed, typically high-resolution.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Engine Specifications
Primary Engine
Engine Type:
2-Stroke
Displacement:
249 cc (250cc class)
Bore X Stroke:
Specific dimensions available in manual, typically around 66.4 x 72 mm for this model.
Cooling System:
Liquid-cooled
Intake:
Reed valve induction, likely with a Mikuni carburetor.
Performance
Horsepower:
Estimated 40-50 HP range, highly dependent on tuning and specific year variations.
Torque:
Peak torque figures typically in the 25-30 lb-ft range.
Fuel System
Carburetor Model:
Likely Mikuni VM38 or similar size for the WR250.
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (specified ratio in manual, e.g., 40:1 or 50:1).
Transmission
Standard
Transmission Type:
6-speed constant mesh manual transmission
Optional
Optional Features:
N/A (Standard configuration for this model).
Features
Clutch Type:
Wet, multi-plate, hydraulically actuated clutch
Gear Ratios:
Specific ratios documented in the manual for each gear.
Transmission Oil Spec:
Manual will specify the correct grade and capacity for transmission lubrication (e.g., SAE 75W/80 or similar).
Dimensions
Exterior
Wheelbase:
Typically around 1470 mm (57.9 inches) for this generation.
Seat Height:
Around 950 mm (37.4 inches) unladen.
Weights
Dry Weight:
Approximately 105-110 kg (231-242 lbs).
Fuel Tank Capacity:
Around 9-10 liters (2.4-2.6 US gallons).
Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA for crashworthiness in the same way cars are).
Active Features
Braking System:
Hydraulic disc brakes front and rear, with specific caliper and rotor sizes detailed in the manual.
Suspension Travel:
Significant suspension travel for off-road capability, front ~290-300mm, rear ~300-310mm.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals (depending on market homologation).
Technology Features
Infotainment
Infotainment System:
N/A (Minimalist off-road motorcycle design).
Driver Assistance
Rider Aids:
N/A (Focus on rider control and mechanical systems).
Connectivity
Connectivity Features:
N/A
Maintenance
Service Intervals
Engine Oil Change:
Every 10-15 hours of riding or annually, specific grade documented in manual.
Air Filter Cleaning:
Recommended after every few rides or as needed based on conditions, detailed cleaning process in manual.
Spark Plug Replacement:
As per manual recommendations, typically based on hours or specific performance degradation.
Chain Adjustment:
Regularly, check for proper tension as per manual specifications.
Fluid Specifications
Coolant:
Ethylene glycol based coolant, mixed with distilled water, specific type and capacity in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid, manual will specify type and procedure for bleeding.
Fork Oil:
Specific viscosity grade (e.g., SAE 5W or 10W) and volume per fork leg detailed in manual.
Known Issues
Common Wear Items:
Clutch plates, piston rings, fork seals, chain and sprockets are typical wear items for a 2-stroke off-road bike.
Carburetor Tuning Sensitivity:
2-stroke engines can be sensitive to altitude and temperature changes, requiring potential jetting adjustments. Manual provides baseline.
Vehicle History
Brand Heritage
Brand Origin:
Swedish, founded in 1903, known for motorcycles, chainsaws, and garden equipment.
Motorcycle Focus:
Long history in motocross and enduro racing.
Model Evolution
Wr Series:
The WR series has been a staple of Husqvarna's off-road lineup for decades, evolving from earlier models.
Generation 2009-2010:
Represents a period where Husqvarna was under Italian ownership (BMW later acquired the brand).
Production
Manufacturing Location:
Italy (during this ownership period).
Awards & Recognition
Recognitions
Brand Awards:
Husqvarna has a long history of winning championships in various off-road disciplines.
Ratings
Review Ratings:
Specific reviews for the 2009-2010 WR 250 would be found in contemporary motorcycle publications, highlighting its performance and handling characteristics.
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