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EN- 7

SPECIFICATIONS - OPERATION - MAINTENANCE

TECHNICAL DATA

ENGINE

Type

...............................................

single cylinder, 2 stroke

Cooling

.........................................................................

liquid

Bore

(250) .................................................2.61 in (66,4 mm)

Bore

(300) ....................................................2.83 in (72 mm)

Stroke

...........................................................2.83 in (72 mm)

Displacement

(250) ....................

15.21 cu. in. (249,3 cm

)

Displacement

(300) ....................

17.87 cu. in. (293,1 cm

)

Compression ratio

(with closed ports) WR 250...............................................8,4:1

(with closed ports) WR 300...............................................6,9:1

Starting

.................................................................

kick start

TIMING SYSTEM

Type

..................................................lamellar valve on suction

H.T.S. valve with mechanical control on the exhaust

lUBRICATION

Engine .......................................... 3% (1:32) of oil-gasoline mix

during running in; NOT lESS than 2% (1:50) when running in is

over

Primary drive transmission/Gearbox by the oil contained in the

crankcase

IGNITION

Type................................. electronic digital capacitor-discharge

type, with variable advance

Spark plug type .....................................................NGK BR8EG

Gap ...................................0.0236÷0.0275 in. (0,6 ÷ 0,7 mm)

FUEl SYSTEM

Type...........................................Carburettor “Mikuni” TMX 38

Venturi diameter ...........................................1.49 in. (38 mm)

High speed jet ....................................................................380

High speed jet (250 USA) ...................................................430

High speed jet (300 USA) ...................................................420

low speed jet ....................................................................17,5

low speed jet (250 USA) ......................................................40

low speed jet (300 USA) ......................................................35

Starting jet ...........................................................................80

Main nozzle ..............................................................R-8 (914)

Floater (n° 2) ..................................................................g 6,1

Throttle piston .....................................................................5,0

Throttle piston (USA) ...........................................................4,0

Metering pin ........................................................... 6BFY43-74

Metering pin (300 USA) ..........................................6GAY69-74

Metering pin slot .................................................................3^

Idle mixture adjusting screw ...........................................1 + ½
PRIMARY DRIVE

Drive pinion gear- Clutch ring gear ..........................Z 27- Z 69

Transmission ratio ..........................................................2,555
ClUTCH

Type

.......

oil bath multiple disc clutch, mechanical control

TRANSMISSION

Type......................................... constant mesh gear type

Transmission ratio

1st gear

........................................................2,142 (z 30/14)

2nd gear

......................................................1,750 (z 28/16)

3rd gear

.......................................................1,437 (z 23/16)

4th gear

.......................................................1,210 (z 23/19)

5 th gear

......................................................1,053 (z 20/19)

SECONDARY DRIVE

Transmission sprocket- Rear wheel sprocket ..............Z 13- Z 48

Transmission ratio ...........................................................3,692

FINAl RATIOS

1st gear ........................................................................20,220

2nd gear .......................................................................16,513

3rd gear .......................................................................13,564

4th gear ........................................................................11,422

5th gear ..........................................................................9,932

FRAME

Type................................ Steel single tube cradle (roud tubes);

light alloy rear frame.

FRONT SUSPENSION

Type....................”Upside-down” telescopic hydraulic front fork

with advanced axle (adjustable in compression and rebound

stroke); stanchions tubes Ø 1.89 in (48 mm).

legs axis stroke

........................................11.8 in. (300 mm)

REAR SUSPENSION

Type...............progressive with hydraulic single shock absorber

Wheel stroke

.............................................12.6 in. (320 mm)

FRONT BRAKE

Type............fixed disc Ø 10.23 in. (260 mm) “Wave” type with

hydraulic control and floating caliper

REAR BRAKE

Type.....................................floating disc, ø 8.66 in. (220 mm)

with hydraulic control and floating caliper

Содержание WR 250 2013

Страница 1: ...Manuale utente_Owner s manual_Manuel d utilisateur_Benutzerhandbuch_Manual del usuario WR 250 WR 250 USA 2013 WR 300 WR 300 USA 2013 ...

Страница 2: ...Ed 05 2012 Rev 00 WR 250 WR 250 USA 2013 WR 300 WR 300 USA 2013 WR 250 WR 300 EN 1 SPECIFICATIONS OPERATION MAINTENANCE EN Unless specified data and prescription are referred to all the models ...

Страница 3: ...7 ALPHABETICAL INDEX 48 PERIODIC MAINTENANCE ADJUSTMENT APPENDIX A Note References to the left or right of the motorcycle are in the sense of a person facing forwards Z number of teeth A Austria AUS Australia B Belgium BR Brazil CDN Canada CH Switzerland D Germany E Spain F France FIN Finland GB Great Britain I Italy J Japan USA United States of America Where not specified all the data and the ins...

Страница 4: ...nder this valuable service This Owner s Manual is part and par cel of the motorcycle hence this had to remain with the motorcycle even when sold to another user This motorcycle uses components designed thanks to sys tems and state of the art technologies which are thereafter tested in competition In competition motorcycles every detail is verified after each race in order to always guarantee bette...

Страница 5: ...this manual carefully and pay special attention to state ments preceeded by the following words WARNING Indicates a possibility of severe personal injury or loss of life if instructions are not followed CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed Note Gives helpful information Parts Replacement When parts replacement is required use only ...

Страница 6: ...n the steering tube Always state the number stamped on the frame and write it on this booklet when placing orders for spare parts or when asking for information on your motorcycle FRAME NUMBER VEHICLE IDENTIFICATION NUMBER V I N The full 17 digit serial or Vehicle Identification Number is stamped on the steering head tube R H side l Model designation Model Year 2013 Progressive no 1 Frame serial n...

Страница 7: ...ONS OPERATION MAINTENANCE control location 1 Front brake lever 2 Throttle grip 3 L H commutator 4 Rear brake control pedal 5 Starting pedal 6 Clutch control lever 7 Fuel tank filler cap 8 Gearbox control pedal 9 Choke L H side 10 Fuel cock ...

Страница 8: ... Floater n 2 g 6 1 Throttle piston 5 0 Throttle piston USA 4 0 Metering pin 6BFY43 74 Metering pin 300 USA 6GAY69 74 Metering pin slot 3 Idle mixture adjusting screw 1 PRIMARY DRIVE Drive pinion gear Clutch ring gear Z 27 Z 69 Transmission ratio 2 555 CLUTCH Type oil bath multiple disc clutch mechanical control TRANSMISSION Type constant mesh gear type Transmission ratio 1st gear 2 142 z 30 14 2nd...

Страница 9: ...hout fuel USA CDN 224 4 lb 102 kg Fuel tank capacity 1 77 Imp Quarts 2 1 U S Quarts reserve included 2 09 Imp Gall 2 51 U S Gall Coolant capacity 0 97 1 14 Imp Quarts 1 16 1 37 U S Quarts Transmission oil 0 70 Imp Quarts 0 85 U S Quarts TABLE FOR LUBRICATION SUPPLIES Engine lubricating oil CASTROL A747 Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 10W 40 Engine coolant CASTROL M...

Страница 10: ... Therefore the fuel filter should be serviced periodically To service 1 Drain the fuel from the fuel tank Disconnect the fuel line 2 Remove the fuel valve by removing the screws Wash the fuel screen filter in cleaning solvent 3 Reassemble the fuel valve in the reverse order of removal Turn the fuel valve ON and check for leaks SIDESTAND A sidestand 1 is supplied with every motorcycle WARNING The s...

Страница 11: ...f gasoline or higher octane grade WARNING Gasoline is extremely flamma ble and can be explosive under certain con ditions Always stop the engine and do not smoke or allow flames or sparks in the area where the motorcycle is refueled or gasoline is stored WARNING Do not overfill the tank After re fueling make sure the tank cap 2 is closed securely CARBURETOR CHOKE The starter knob 1 located on the ...

Страница 12: ...e instrument doesn t also show its functions To select the instrument functions and to set to zero the functions use the SCROLL knob A The instrument functions are the following as shown below 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED CHRONO 1 SPEED ODO 1 SPEED Km h or mph ODO SPEED motorcycle speed maximum value 299 Km h or 299 mph ODO odometer maximum value 99999 km To replace kilometers wi...

Страница 13: ... 1 distance maximum value 999 9 km the data will be lost with voltage lower than 6V To setup the TRIP push the SCROLL A button holding down more than 3 seconds 4 SPEED CHRONO STP SPEED motorcycle speedmaximum value 299 Km h o 299 mph STP 1 miles kilometers covered time Reading from 0 00 to 99 59 59 the data will be lost with voltage lower than 6V To activate the function STP 1 push the knob SCROLL...

Страница 14: ...ght hand side of the handlebar The position of the throttle control can be ad justed by loosening the two fastenig screws B CAUTION Do not forget to tighten the screws B after the adjustment STEERING LOCK The motorcycle is equipped with a steering lock 1 on the R H side of the steering head tube To lock it procede as follows turn the handlebar leftwards place the key in lock and turn counterclockw...

Страница 15: ...Lighting control of lowbeams and high beam Lighting control of position lights Off ENGINE STOP BUTTON USA On the left side of the handlebar near the clutch control is lo cated the engine stop button 1 CLUTCH CONTROL The clutch lever is located on the left hand side of the handlebar and is protected against dirt filtering in The lever support is pro vided with adjusting screw 1 to regulate clutch w...

Страница 16: ...nd gears First gear is engaged by pushing the lever downwards all the other gears are engaged by pushing the lever upwards The position of the gear shift lever on the shaft can be varied by loosening screw pulling lever out placing lever in new position on the shaft when the operation is over tighten the screw and then tightening the screw CAUTION Do not shift gears without disen gaging the clutch...

Страница 17: ...nt RUNNING IN To obtain the best settling of the engine moving elements for driving your motorcycle to the best of your capability run in the engine for several hours following these procedures 1 FROM STOP POSITION Start the engine and run at idle but open the throttle periodically and briefly until the engine is tho roughly warmed up Within 3 4 minutes the coolant temperature will have reached ap...

Страница 18: ...ve the spark plug and dry it IMPORTANT NOTE IN CASE OF COLD STARTS AT LOW TEMPERATURES It is recommended to briefly warm up the engine at idle until after having dis engaged the starter there is a normal response from the engine when opening the throttle This will enable the lubricant to reach the correct working temperature there by guaranteeing a correct functioning of all engine parts Avoid ove...

Страница 19: ...help slow down the motorcycle For normal braking gradually apply both front and rear brakes while down shifting for maximum deceleration apply the front and rear brakes firmly When stopped pull the clutch lever and shift gear lever 2 in neutral position Press the engine stop button 3 Close the fuel cock 4 When the bike is off place it on its side stand ...

Страница 20: ...d pour fresh oil from the hole of the loading plug Use only the prescribed quantity and type of oil Note Have this operation made with warmed up engine A Draining plug COOLANT LEVEL CHECK Check level 1 in right hand radiator when engine is cold place the motorcycle so that it is perpendicular to the ground The coolant should be approximately 10 mm above cells The radiator cap is provided of two un...

Страница 21: ...uantity of liquid in the radiator warm up the motor in order to eliminate any possible air bub ble fit the motor in vertical position and check that the liquid in the radiators must be 10 mm 0 4 in over the radiant mas if not top it up screw the R H radiator plug WARNING Coolant on tires will make them slippery and can cause an accident or injury Periodically check the connecting hoses see Periodi...

Страница 22: ...ovement to allow for correct adjustment then adjust register placed on carbu retor There should be approx 1 mm play on latter register should this not be the case then loosen lock nut 3 and loosen or tighten screw 4 to respectively increase or decrease the play WARNING Operation with damaged throt tle cable could result in an unsafe riding con dition IDLING ADJUSTMENT Idling should be adjusted onl...

Страница 23: ... adjust this clearance act on register 2 after taking out rubber cap 1 turn the register in the direction indicated by arrow A to reduce the clearance C turn it in the direction indicated by arrow B to increase the clearance 1 Rubber cap 2 Adjusting screw The adjustment can be also effected with tightener 1 set on the right of the frame Take care to tighten properly the lock nut If the clutch slip...

Страница 24: ...r should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the spark plug is overheated and insulator tip is vitre ous white or grey in colour CAUTION Select a spark plug with a colder or hotter heat range carefully and cautiou sly A spark plug with too hot a heat range may lead to ...

Страница 25: ...erfluous oil CAUTION Do not use gasoline or a low flash point solvent to clean the element A fire or explosion could result CAUTION Clean the element in a well ven tilated area and do not allow sparks or flames anywhere near the working area ASSEMBLY To ensure tight fit slightly C grease filter edge on side facing filter housing While re inserting the filter into its housing make surs that piece A...

Страница 26: ...lso rotate without effort Stand in front of the motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis Se si avverte gioco occorrerà eseguire la regolazione operando come segue loosen steering sleeve nut 1 Loosen screws that fix steering head to fork rods 3 Turn the steering ring nut 2 clockwise of the steering sleeve proper tool to adjust play prope...

Страница 27: ...et air into the sustem hence an extension of the level stroke WARNING If the brake lever feels mushy when it is applied there may be air in the brake lines or the brake may be defective Since it is dangerous to operate the motorcycle under such conditions have the brake checked immediately by an authorized HUSQVARNA dealer CAUTION Do not spill brake fluid on to any painted surface or lenses CAUTIO...

Страница 28: ...ried out adjust the idle stroke of the pedal as follows Rear brake idle stroke adjustment The rear brake foot pedal should have a B 5 mm 0 2 in idle stroke before starting the true braking action Should this not happen operate as follows loosen nut 3 operate the pump rod 4 to increase or decrease the idle stroke tighten nut 3 at the end of the operation WARNING When the idle stroke figures are not...

Страница 29: ...tment and a harder extension adjustment at the same time Shock absorber have a harder compression and expecially a harder extension adjustment Work on the spring preload to lower the motorcycle rear side MUDDY GROUND Fork have a harder compression adjustment or replace the standard spring with a harder one Shock absorber have a harder compression and extension ad justments or replace the standard ...

Страница 30: ...clockwise Reverse the operation in order to obtain a harder action c AIR VENT to carry out after each competition or monthly Set the motorcycle on a central stand and release the fork fully and loosen the air vent valve D Once this operation is over tighten the valve WARNING Never force the adjusting screws beyond the maximum opening and closure positions OIL FORK LEVEL For the regular fork operat...

Страница 31: ...w distance A 4 The difference between these two measurements constitutes the SAG of the motorcycle s rear end Suggested SAG 4 in with cold shock absorber 3 7 in with warmed up shock absorber 5 To get the right SAG according to your weight adjust the shock absorber spring preload as described at side WARNING Never disassemble shock ab sorber which contains highly compressed nitrogen Contact your De...

Страница 32: ...rom the rebound stroke A COMPRESSION Standard calibration 1 Low damping speed 15 clicks 2 clicks register 4 2 High damping speed all open register 6 To reset the standard calibration turn upper registers 4 and 6 clockwise until reaching fully closed position Return then back for the mentioned clicks In order to obtain a smooth braking action turn the registers anticlockwise Reverse the operation i...

Страница 33: ...eel pin 1 on the right side Unloose the lock nuts 2 on both chain adjusters and turn the screws 3 to obtain the correct tension value Tighten the lock nuts After adjustment check that the wheel is lined up and tighten its axle Fig A Drive sprocket axle Rear swing arm axle Rear wheel axle Fig B Normal consumption Excessive consumption CHECKING THE WEAR OF CHAIN PINION AND SPROCKET Check the pinion ...

Страница 34: ...sing oil diesel oil or paraffin oil Never use gasoline tricloroetilene or solvents as the OR may suffer damages Use instead special sprays for chains with OR Lubricating the chain with OR Lubricate all metallic and rubber OR elements using a brush and use engine oil with SAE 80 90 viscosity for the internal and external parts Note As an alternative you can use suitable spray lubri cants 5 Assemble...

Страница 35: ...ground Loosen the bolts 1 holding the wheel axle 2 to the front fork stanchions Hold the head of the wheel axle 2 in place unscrew the bolt 3 on the opposite side draw the wheel axle out NOTES Do not operate the front brake lever when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top ...

Страница 36: ...n the L H leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg 10 4 Nm 1 05 Kgm 7 7 ...

Страница 37: ...rear wheel by taking care of the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the disc into the caliper NOTES Do not operate the rear brake pedal when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top After reassembly pump the brake control pedal until the pads are a...

Страница 38: ...yre inflation pressure BRAKES The mayor components are brake master cylinder with its lever front or pedal rear brakeline caliper assembly and disc LEGEND 1 Front brake control lever 2 Front brake pump with oil reservoir 3 Front brake hose 4 Front brake caliper 5 Front brake disc 6 Rear brake oil tank 7 Rear brake hose 8 Rear brake caliper 9 Rear brake disc 10 Rear brake pump 11 Rear brake control...

Страница 39: ... FRONT BRAKE PADS REMOVAL Remove springs 1 Remove pins 2 Remove pads CAUTION Don t operate the brake lever or pedal while removing the pads PADS WEAR Inspect pads for wear Service limit A is 3 8 mm 0 15 in If service limit is exceeded always replace the pads in pairs ...

Страница 40: ...h alcohol Replace the pads with new ones if they cannot be cleaned sat isfactorily PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the springs 1 WARNING Do not attempt to ride the motorcycle until the brake lever or pedal are fully effective Pump the brake lever or pedal until the pads are against the discs The brake will not function on the first ap plication of the lever o...

Страница 41: ... mm 0 16 in 0 14 in BRAKE DISC WEAR Measure the thickness of each disc at the point where it has worn the most Replace the disc if it has worn past the service limit Disc Thickness DISC WARPAGE Measure disc warpage Service limit for both discs is 0 15 mm 0 006 in Replace the disc if warpage is more than service limit ...

Страница 42: ...TIONS OPERATION MAINTENANCE EN DISC CLEANING Poor braking can also be caused by oil on the disc Oil or grease on the disc must be cleaned off with a high flash point oil free solvent such as acetone or lacquer thinner ...

Страница 43: ... the instrument panuel support 1 push forward the headlamp carrier B and pull it towards the high C in order to uncouple from the two lower supports remove the headlamp carrier remove the two filaments bulb connector 2 and the boot 3 release the bulb holder clips 4 and take out bulb 5 To replace the parking light bulb 6 extract it from the inside cover After replacement reverse operations for reas...

Страница 44: ...lace it when it does not func tion REPLACING THE NUMBER PLATE BULB loosen screw 1 and remove the number plate bulb 2 from the mudguard take bulb holder 3 and bulb 4 out of the support pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassemble ...

Страница 45: ...itudinal axis 10 meter 33 ft from a wall or screen Then trace an horizontal line equal to the height of headlight center and a vertical one in line with its longitudinal axis If possibile execute this operation in a shadowy place When the low beam is on the upper boundary limit between dark and lit zone should be 9 10 th of headlight center from groud Adjust the preadlamp aiming by turning screw 1...

Страница 46: ...il on rubber parts or in the brakes Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards un der the front and rear wheels to keep dampness away from the tire rubber Tie a plastic bag over the exhaust pipe to prevent moisture from entering Put a cover over the motorcycle to keep dust and dirt from collecting on it To put the motorcycle...

Страница 47: ...eTable AppendixA Start the engine and run it for 5 minutes Test the brakes before riding the motorcycle WARNING Never wax or lubricate the brake disc Loss of braking and an accident could result Clean the disc with an oilless solvent such ans acetone Observe the solvent warn ings After each cleaning it is recommended the use of a water repellent product suitable for electrical contacts see table f...

Страница 48: ...o serraggio Fascette stringitubo Controllo serraggio Lubrificazione generale Collaudo generale Engine oil Check level Two stroke mix oil level Check level Coolant Check Restore level Cooling system Check for leakage Electric fans Check operation Spark plugs Check Replace Throttle body Carburettor Check and adjust Brakes Clutch fluid Check level Brakes Clutch Check operation Brakes Clutch Check lin...

Страница 49: ...eck of the front brake fluid level 26 After race check points 45 Air filter check 24 Air filter and cleaning 24 Appendix 45 Assembly 24 B Before every ride make following checks 16 Brake disc wear 40 Brake pads removal 38 Brakes 37 C Carburetor choke 10 Chain adjustment 32 Checking the fluid level 27 Checking the wear of chain pinion and sprocket 32 Checks while running in 16 Cleaning 45 Clutch ad...

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